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1. 17 Nm 16 Slide output shaft support bearing inward against frame Be sure to hold bearing square with shaft 17 Visually inspect gap between frame and upper or lower mounting boss on support bearing If a gap exists on upper or lower boss measure with a feeler gauge and add shim s as required to maintain proper alignment when mounting nuts are tightened Torque to specification Mounting Nut Torque 18 ft Ibs 25 Nm Shim Kit PN 2200126 includes 2 5210764 020 2 5210759 063 2 5210760 080 18 Apply silicone to splines of brake disk and reinstall disk 19 Install brake caliper on disk and bolt to frame with the rear caliper shield Torque to specification Caliper Attaching Bolt Torque 12 ft Ibs 17 Nm Gp POLARIS TRANSMISSION 8 13 TRANSMISSION T RANSMISSION INSTALLATION CONT 20 Install snap ring onto output shaft securing brake 21 22 23 24 25 26 27 disk Install sprockets and middle chain Install sprocket with bolt lock washer and retaining washer and torque output shaft sprocket bolt to 17 ft lbs 23 Nm Torque center eccentric sprocket bolt to 30 ft lbs 41 Nm Install chain guard with spacer Adjust rear and center chains Refer to Maintenance Section for details Install brake disk cover Install top mounting bolts of brake disk cover rear caliper shield and caliper to frame Torque caliper mounting bolts to 12 ft Ibs 17
2. RTV silicone to cure Gp POLARIS Cap Scre ew gt Knob Seal with Clamps RTV silicone E M Boot Cover Apply t E gt Loctite 515 Spring Handle Striker Assembly 1 y Stop Pin Detent Spring Bearing Cup Detent Pin N Interlock rin C3 Selector Switch Interlock z Ng S i Butterfly EH High Reverse Te 8 Notches 2 Notches Bde Slides 8 5 TRANSMISSION TRANSMISSION REMOVAL Remove seat cab and air box 2 Remove right side shield 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 carburetor 6 Remove drive chain and sprocket 7 Remove mounting bolts as shown 8 Remove through bolt from bottom of transmission 9 Loosen left side swingarm bolt until clear of transmission case 10 Remove recoil 11 Remove transmission from right side of frame 8 6 Gp POLARIS TRANSMISSION TRANSMISSION DISASSEMBLY 1 Remove speedometer angle drive sprocket retaining circlip and sprocket 2 Remove the transmission cover bolts 3 With a soft face hammer tap on the cover bosses and carefully remove the cover See Ill 1 Loi Tap with soft face hammer Ill 1 4 Using the battery cable clamp puller remove the bearing from the sliding gear shaft See Ill 2 5 Remove outer thrust washer 55 P Puller Ls ll 2 6 To remove the needle
3. bearing from the low gear tip transmission to point end of shaft downward Work gear back and forth as shown until bearing is exposed and slide bearing out See Ill 3 Low Gear 2 Remove needle bearing T rl u 1 Work gear back and forth until bearing is exposed lll 3 TRANSMISSION TRANSMISSION DISASSEMBLY CONT 7 Remove the low gear and inner thrust washer 8 Use a 1 2 wrench on gearshift bell crank retaining nuts to aid in moving the shift fork shaft 9 Remove the low range shift fork shaft with engagement dog by rotating the low gear shift arm clockwise and pulling outward on shift fork shaft NOTE High Reverse bell crank must be in neutral to re move Low gear shift fork shaft 10 Remove output shaft and gear assembly by tapping on shaft with a soft faced hammer from the back side of the gear case assembly TRANSMISSION TRANSMISSION DISASSEMBLY CONT 11 Remove sliding gear shaft with high reverse shift shaft and input shaft as an assembly by gradually pulling assemblies from their bearing mounts while rotating the high reverse shift arm counterclockwise Oil Deflector NOTE Make sure input shaft gear clears oil deflector but do not remove the oil deflector 12 Clean all components in a parts washer and inspect for wear 13 Inspect engagement dogs of gears and replace if edges are rounded 14 Inspect gear teeth for wear cracks chips or
4. broken teeth 15 Remove seals from transmission case NOTE New seals should be installed after the transmis sion is completely assembled 16 Inspect bearings for smooth operation Check for excessive play between inner and outer race TRANSMISSION TRANSMISSION ASSEMBLY 1 Carefully install high reverse shaft assembly and gear cluster as a unit into their respective bearing case areas Make sure input shaft clears oil deflector Tap with a soft face hammer to seat shaft assemblies NOTE Make sure high reverse shift shaft pin is properly positioned within legs of shift fork shaft return spring 2 Seat the shafts and shift the assembly into neutral position NOTE After installation the High Reverse shift arm must be placed in the neutral position to complete reas sembly 3 Install the output shaft and gear assembly into the gear case 4 Install engagement dog on low range shift shaft NOTE Dogs should face toward the mating gear 5 Install low shift shaft assembly aligning pin on shift shaft between ends of return spring the engagement dog splines with the sliding gear shaft splines and the end of shift shaft to the gearcase See Ill 1 Engagement dog splines Ng Large I D Shaft pin IL 6 Install large I D washer on shaft against splines 8 10 0 X lin inside 1g e Gp POLARIS TRANSMISSION TRANSMISSION ASSEMBLY CONT 7 Install low
5. gear on shaft with engagement dogs inward 8 Lubricate and install needle bearing into gear Needle Bearing 9 Install smaller I D washer and then ball bearing NOTE The bearing should be flush with the shaft when seated correctly 10 Prior to reinstalling the cover make sure the mating cover surfaces are clean and dry Apply Loctite 518 or 3 Bond 1215 to mating surfaces 11 Reinstall cover and torque bolts in 3 steps to 12 ft Ibs 17 Nm using a criss cross pattern 12 Install transmission and add 20 oz of Polaris Premium Synthetic Gear Case Lubricant Transmission Capacity 20 Oz Premium Synthetic Gear Case Lubricant PN 2871178 12 oz PN 2870464 Gallon TRANSMISSION TRANSMISSION INSTALLATION 1 Installtransmission from right side of ATV with output shaft side down and input shaft side up toward right rear corner of frame NOTE As you are guiding the output shaft into its mount ing the rear drive chain can be installed onto shaft and sprocket Make sure chain is properly positioned on axle sprocket 2 Loosely install lower mounting bolt and nut CAUTION Be sure bolts are proper length or transmission damage may occur 3 Loosely install right side 3 8 16 x 3 4 mounting bolt in top right hole 4 Attach washer nut and roller chain guide to the right side swing arm bolt 5 Align transmission case bushing with bolt and torque nut to 55 ft Ibs 76 Nm B
6. rod ends clevis pins or pivot arm bushings e Linkage rod adjustment and rod end positioning Worn broken or damaged internal transmission components NOTE To determine if shifting difficulty or problem is caused by an internal transmission problem isolate the transmission by disconnecting linkage rods from transmission bellcranks Manually select each gear range at the transmission bellcrank and test ride vehicle If it functions properly the problem is outside the transmission If transmission problem remains disassemble transmission and inspect all gear dogs for wear rounding dam age Inspect all bearings for wear
7. CHAPTER 8 TRANSMISSION SERVICE Torque Specifications 8 1 Gear Shift Selector Removal 8 2 Gear Shift Selector Disassembly 8 2 8 3 Gear Shift Selector Assembly 8 4 Gear Shift Selector Installation 8 5 Boot Replacement paaa Pada ana 8 5 Transmission Removal sess 8 6 Transmission Disassembly 8 7 8 9 Transmission Assembly 8 10 8 11 Transmission Installation 8 12 8 14 Transmission Exploded View 8 15 Troubleshooting 8 16 TORQUE SPECIFICATIONS Transmission Case Bolts a 12 ft Ibs Bell Crank Nut o scs cete e ET meten eot dms 12 ft Ibs Transmission Drain Plug sese 14 ft Ibs Speedometer Angle Drive 11 ft Ibs Transmission Mounting Boite 25 ft Ibs Drive Sprocket Bolt 17 ft Ibs Output Shaft Bearing Mounting Nuts 12 ft Ibs Swing Arm Pivot Bolts 00 ec eee eens 55 ft Ibs LUBRICATION Refer to maintenance section for transmission lubricant type and capacity Gp POLARIS TRANSMISSION 16 6 Nm 16 6 Nm 19 3 Nm 1 52 kg m 34 5 Nm 23 5 Nm 16 6 Nm 7 59 kg m 8 1 TRANSMISSION GEAR SHIFT SELECTOR REMOVAL NOTE The shift selector switch can be replaced with the shift selector box remaining in the frame To change fluid remove selector box assembl
8. Nm Attach brake caliper arm to moveable cam and adjust foot pedal to 1 2 deflection See Maintenance Section Lock the jam nut Install air cleaner assembly making sure carb boot seals on air box correctly Tighten hose clamp Reinstall pre cleaner duct work and pre cleaner Proceed with linkage rod adjustment found in the Maintenance Chapter 2 Output Shaft Bearing Retaining Bolt Torque 17 ft Ibs 23 Nm Brake Caliper Attaching Bolt Torque 12 ft Ibs 17 Nm Output Shaft Sprocket Bolt Torque 17 ft Ibs 23 Nm Center Eccentric Sprocket Bolt Torque 30 ft Ibs 41 Nm 8 14 Gp POLARIS TRANSMISSION TRANSMISSION EXPLODED VIEW Input Shaft Seal Bushing Shift Fork E Shaft High Rev zu Low Shift Shaft Seal Upper Rearmost Shift Fork on Transmission Shaft Low Bell Crank ics Washer O Ring High Reverse Shift Shaft Lower Forward most on Transmission Detent Spring High Reverse verse i Engagement Dog NI e Bal SH i N EN EN man MU Vent O Ring C MEN Bushing Dipstick Output Shaft Seal Gp POLARIS 8 15 TRANSMISSION TROUBLESHOOTING CHECKLIST Check the following items when shifting difficulty is encountered Idle speed adjustment Transmission oil type quality Transmission torque stop adjustment Engine torque stop adjustment Drive belt deflection Loose fasteners on rod ends Loose fasteners on shifter Worn
9. ear shift selector switch from gear shift selector body 5 Remove the white plastic bearing cup and three springs from gear shift selector 6 Slowly tilt gear shift selector body sideways to drain oil NOTE Do not tip gear shift selector body upside down or detent bullets and stop pin may fall out Check for signs of moisture in the selector body Inspect shift boot closely if moisture is present in selector box 7 Tap gear shift selector body top down against a hard smooth flat surface to jar the stop pin and two detent bullets loose Pull the detent bullets and the stop pin out of the gear shift selector body 8 Hold the interlock butterfly out of the way and Clamps remove the two slides one at a time 9 Remove interlock butterfly and inspect for wear or T Boot damage NOTE The LH slide has two notches and the RH slide Cover Apply has three The slides must be replaced in the proper a _ Logtite 515 channels Spring oD A 10 Inspect O rings for damage Replace if any damage is found 11 Flush housing with parts washer fluid or penetrating oil to remove all moisture 12 Dry all gear shift selector parts and remove any corrosion with a wire brush Bearing Cup Interlock D p4 Selector Switch Interlock 7 Ng Ke Butterfly S High Reverse awn 3 Notches Handle Striker Assembly Detent Spring Detent Pin 2 Notches ot Slides TRANSMISSION GEAR SHIFT SELECTOR ASSEMBLY 1 Ins
10. end the tab washer to lock the bolt in place 6 Loosely install left side 3 8 16 x 3 4 top mounting bolt Install washer and nut on the left side swing arm bolt Align transmission case bushing with bolt and torque nut to 55 ft lbs 76 Nm Bend the tab washer to lock the bolt in place 9 Align transmission with engine See Clutch Section for center distance and alignment procedure Torque lower mounting bolt to 25 ft Ibs 85 Nm Torque right and left 3 8 16 x 3 4 bolts to 25 ft lbs 85 Nm 10 Adjust torque stop by adjusting bolt until it contacts the frame Then tighten an additional one half turn using a wrench Hold the adjuster bolt and tighten the jam nut 11 Attach speedometer cable to angle drive and tighten 12 Install skid plate and torque bolts to 5 ft Ibs 7 Nm 13 Install driven clutch spacer and dust seal s 14 Install inner cover and all PVT system components Refer to PVT Section for procedure 8 12 Qd m FIG rene Drive Key lt Adapter LH Thread G Drive Key e 8 10 ft Ibs 1 10 1 38 kg m Gp POLARIS TRANSMISSION INSTALLATION CONT 15 Grease support bearing and install on output shaft Swing Arm Bolt Torque 55 ft Ibs 76 Nm Transmission Mounting Bolt Torque 25 ft Ibs 35 Nm Skid Plate Bolt Torque 5 ft Ibs 7 Nm Inner Cover Bolt Torque 12 ft Ibs 17 Nm Drive Clutch Torque 40 ft Ibs 5 5 Nm Driven Clutch Torque 12 ft Ibs
11. r body Make sure slides are in neutral or butterfly may be damaged CAUTION Be very careful not to damage the selector switch while assembling these parts Tab end of selector switch must be positioned in hole of striker as shown at right If not assembling cover will damage switch Torque cover screws to 12 ft Ibs 1 7 kg m TRANSMISSION GEAR SHIFT SELECTOR INSTALLATION 1 Place gear shift selector back into the mounting bracket and replace three bolts Reconnect linkage rods to gear shift selector slides Adjust as required See linkage adjustment procedures Route gear shift selector switch wiring harness properly and secure in place with cable ties Reconnect the wiring harness leads Secure the gear shift selector switch wiring harness to the frame Replace remaining parts BOOT REPLACEMENT NOTE If moisture is found in the gear shift selector the boot should be replaced 1 Using a slotted screwdriver remove cap from gear shift knob Remove torx screw securing knob to selector rod Pull selector knob off selector rod Remove band clamps on rubber boot Slide boot off selector rod and replace with a new one Apply RTV silicone to selector rod to seal top of boot Place band clamps in position and tighten using CV boot clamp pliers Replace shift knob securing it to selector rod with screw removed in step 2 Push shift knob cover back into place Allow approximately 12 hours for
12. tall interlock butterfly 2 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 notches and the RH side has three The slides must be replaced in the proper channels for the shifter to function properly 3 Replace detent bullets stop pin springs and white plastic bearing cup by reversing steps 5 7 of Gear Shift Selector Disassembly 4 Clamp gear shift selector body lightly in a soft jawed vise 5 Fill selector body with Polaris OW 40 All Season Synthetic motor oil The oil level should be at one half the height of the slides approx 1 oz Gear Shift Selector Capacity 1 oz Polaris OW 40 All Season Synthetic Oil PN 2871281 Quart PN 2871844 Gallon CAUTION Too much oil could cause the selector to hy drolock Be sure the selector box is level when adding oil Switch Positioned 6 Carefully reinstall the gear shift selector switch The hook on the switch faces downward toward shift slides This hook catches on the selector body to prevent the switch from moving out of place NOTE Switch must be positioned properly or AWD may not function 7 Wipe gear selector dry clean surfaces of cover and selector box with Loctite Primer T and place a bead of Loctite 518 Gasket Eliminator or 3 Bond 1215 completely around the edge of the gear shift selector body 8 Carefully reattach cover rod assembly to gear shift selecto
13. y disassemble clean and assemble 1 Remove parts that interfere with access to shift selector seat right side panel and exhaust heat shield etc 2 Disconnect wiring harness noting the location and routing of the wires 3 Pull wiring harness through to gear shift selector side of machine 4 Disconnect the two linkage rods from gear shift selector slides 5 Remove three bolts attaching gear shift selector to the mounting bracket 6 Liftgear selector out of mounting bracket and away from frame GEAR SHIFT SELECTOR DISASSEMBLY CAUTION Wear eye protection during this procedure Read each step completely before proceeding Essential parts may be lost or damaged if you do not heed this caution 1 Clamp gear selector body lightly in a soft jawed vice Using a criss cross pattern loosen each of the five screws holding the gear shift selector cover to the gear shift selector body Loosen each screw only a few turns then proceed to another Screw NOTE These parts are under pressure from the inter nal spring TRANSMISSION GEAR SHIFT SELECTOR DISASSEMBLY CONT 2 Carefully pull the gear shift selector cover and rod from the gear shift selector body CAUTION Be very careful to pull the cover away verti cally and slowly to avoid damage to the internal gear selector switch The selector switch is easily dam aged 3 Set the cover rod assembly aside 4 Very carefully remove the g

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