Polaris 2005 Sportsman MV7, Service Manual

Page: 229 / 312

TRANSMISSION
8.13
NOTE: Install a new snap ring at this time. When
installing the new snap ring, open the the snap ring
just far enough to go over the shaft, to avoid stressing
the snap ring. If the snap ring is over--stressed, it
could come off the shaft and cause internal damage
to the transmission.
10. Slide the reverse shaft assembly through the
silent chain.
11. Install a new needle bearing, the low gear, the
thrustwasher and the snap ring. Use of a new
snap ring is recommended.
12. Install the engagement dogs, wave springs, and
bearing.
13. Install the ball bearing onto the end of the input
shaft.
14. As the engagement dogs are installed onto the
shaft, place the wave springs into the spring
groove. Keep the spring in place while the fork is
being installed on the shaft and while placing the
shafts into the case.
NOTE: Use caution when installing the fork, as the
spring can easily fall out.
NOTE: Installing the shift rail will aid in keeping the
shift forks, shift dogs, and the springs in place.
15. Carefully install the shaft assembly and gear
cluster as a unit into their respective bearing case
recesses. Tap with a soft face hammer to seat
shaft assemblies.