Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 203 / 289

TRANSMISSION
8.5
TRANSMISSION REMOVAL
1. Remove seat, cab and air box.
2. Remove right side shield and auxiliary brake
master cylinder and reservoir.
3. Remove PVT outer cover, both drive and driven
clutch, and inner PVT cover (refer to Clutch
Chapter 6).
4. Remove rear PVT bracket.
5. Remove pin from front prop shaft at front housing.
Position U-joint to allow pin to clear skid plate.
6. Remove carburetor.
7. Disconnect harness from gear position switch.
8. Remove drive chain and sprocket.
9. Remove mounting bolts and brackets as shown.
10. Remove
through-bolt from bottom of
transmission.
11. Loosen left side swingarm bolt until clear of
transmission case.
12. Remove recoil.
13. Remove transmission from right side of frame.
TRANSMISSION
INSTALLATION
1. Reverse removal steps to install transmission.
NOTE: Install the 10” Center Distance Tool (PN
2871710) on engine and transmission input shaft
before tightening transmission mounting bolts. Align
clutches as outlined in Clutch Chapter 6.
TRANSMISSION
DISASSEMBLY
1. Place both bellcranks in neutral position.
2. Remove sprocket retaining clip and sprocket.
CAUTION: Remove switch(es) BEFORE
removing case cover.
3. Remove the transmission cover bolts.
Ill. 1
Tap with soft
face hammer
Remove Gear Indicator Switches
4. With a soft face hammer tap on the cover bosses
and carefully remove the cover. See Ill. 1.
Ill. 2
Puller
Bearing
5. Using the battery cable clamp puller, remove the
bearing from the sliding gear shaft. See Ill. 2.