Polaris Outlaw 500, Service Manual

Page: 73 / 202

3.26
ENGINE
TRANSMISSION AND CRANKSHAFT
SERVICE
Transmission Removal and Inspection
1. Remove the shift fork tubes, spring, shift forks, and shift
drum from the transmission assembly.
2. Remove the main and output transmission shaft assemblies
and disassemble, keeping the parts in order for ease of
reassembly. Inspect the shift forks, shift drum, shift dogs,
gear teeth and shaft splines for damage. If the mating
surfaces on any of the components are found to be rounded,
worn, or otherwise damaged, they must be replaced.
3. Inspect the shaft support bearings in the crankcase halves.
Replace if any roughness or wear is felt. See page 3.25 for
crankcase bearing inspection / removal.
4. To reassemble, reverse the procedures using the photos for
reference.
Transmission Main Shaft Disassembly /
Assembly
1. Attach a bearing splitter to the reverse gear ONLY as
shown.
DO NOT apply a load to 4th gear, as damage will
result. Place the assembly into a hydraulic press and using
a suitable driver, press off the gear.
2. Remove the parts from the shaft, keeping them in order for
ease of reassembly. Inspect all the main shaft components
for signs of damage or wear. If the mating or rolling
surfaces on any of the components are found to be rounded,
worn, or otherwise damaged or rough, they must be
replaced.
Main Shaft Assembly
Output Shaft Assembly
CAUTION
These procedures require the use of a heat
source and hydraulic press to remove and install
components. Wear the proper protective and
safety gear to prevent injury.
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