Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 313 / 432

8.7
TRANSMISSION
8
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Shift Linkage Inspection
1. Inspect shift linkage rod bushing clips and replace if
worn or damaged. Lubrication of rod ends is not
required.
Gear Selector Removal
1. Push linkage rod out of bushing clip to remove.
2. Remove screws attaching gear selector mount to
frame.
3. Remove gear selector handle by prying the cover off
and removing the retaining screw.
Transmission Removal
1. Place vehicle in “park”. Raise and securely support
rear of ATV under the frame. Remove both rear
wheels.
2. Disconnect the BLACK (negative) battery cable from
the battery.
3. Remove:
• Seat
• Side Panels
• Rear Rack/Rack Support
• Rear Cab Assembly
• Left/Right Foot Wells
4. Disconnect the vehicle speed sensor and gear
selection switch connectors from the transmission.
5. Disconnect transmission vent hose from the nozzle.
6. Disconnect shift rod end from transmission bellcrank.
7. Remove PVT outer cover, drive and driven clutches,
and the inner PVT cover. (refer to Clutch Removal in
Chapter 6).
8. Remove fasteners securing upper control arms to
stabilizer brackets and transmission brackets.
9. Remove the stabilizer bar links from the upper control
arms. Remove lower shock-to-control arm fasteners.
10. Remove both rear drive shafts from transmission.
11. Remove the fasteners securing the stabilizer
assembly to the upper frame.
12. Remove the two mounting bolts that secure the front
of the transmission to the frame.
13. Remove all lower transmission mounting fasteners
from each side.
14. Remove the upper transmission support bracket
completely from the ATV.
15. With the help of an assistant, lift and remove
transmission out of rear of frame while pulling the
output shaft from the propshaft yoke.
Linkage Rod
Bushing Clip
Bushing Clip
Linkage Rod
Cover
Screw
Knob
Shift
Handle
Mount
Bushing Clip
Screw