Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 201 / 289

TRANSMISSION
8.3
two detent bullets loose. Pull the detent bullets
and the dowel pin out of the gear shift selector
body.
7. Remove the two slides, one at a time.
NOTE: The LH (low) slide has two short notches and
the RH (high/rev) slide has one short and one long
notch. The slides must be replaced in the proper
channels.
Knob
Screw
Cap
Clamp
Boot
Cover (Apply
Loctite
t
515)
Dowel
Pin
Handle
Selector Slides
Low
2 Short
Notches
High/Reverse
(1 Short,
1 Long Notch)
Detent Spring
Detent
Bullet
Centering Spring
Plastic
Sphere
Detent
Spring
Detent
Bullet
Groove
Pin
8. Inspect O-rings for damage. Replace if any
damage is found.
9. Flush housing with parts washer fluid or
penetrating oil to remove all moisture.
10. Dry all gear shift selector parts and remove any
corrosion with a wire brush.
GEAR SHIFT SELECTOR
ASSEMBLY
1. Insert slides into gear shift selector body, taking
care not to cut or tear O-rings in the process.
NOTE: The LH slide has two short notches and the
RH side has one short and one long notch. The slides
must be replaced in the proper channels for the shifter
to function properly.
2. Replace detent bullets, dowel pin, and springs by
reversing Steps 5-7 of Gear Shift Selector
Disassembly.
3. Clamp gear shift selector body lightly in a soft
jawed vise.
4. Fill selector body with Polaris 0W-40 All Season
Synthetic motor oil. The oil level should be at one
half the height of the slides (approx. 1 oz.).
Polaris 0W-40 All Season Synthetic Oil
(PN 2871281) - Quart
(PN 2871844) - Gallon
Gear Shift Selector Capacity: 1 oz.