Polaris 2007 SPORTSMAN X2 800 User Manual

8.25
Sportsman X2 Transmission
8
Transmission Installation
1. Apply Polaris Premium All Season Grease (PN 2871423)
to splines of front output shaft ,install new O–ring in prop
shaft.
2. With the help of an assistant, rotate transmission into place
from the right side of the frame, aligning the forward
transmission bracket into the rear engine mounting holes
while ensuring that the output shaft and propshaft align and
slide together.
3. Loosely install lower transmission mounting fasteners and
forward engine mounting nuts.
4. Install the rear support bracket, middle support bracket and
torsion bar support bracket. Torque all lower bracket bolts
to specification. Torque all upper rear and middle support
bracket bolts (circled) to specification.
5. Install the upper control arms. Refer to Chapter 5 for
procedures and torque specifications.
6. Reconnect the torsion bar to both lower control arms.
Torque to specification.
7. Install both upper shock absorber mounts and torque to
specification.
8. Apply anti-seize to splines of rear drive shafts and insert
drive shafts into carriers and transmission. Install rear
carriers and hubs.
Torque lower carrier bolts to specification. Torque all other
control arm bolts and remaining carrier bolts to
specification.
= T
Transmission Bracket Bolt Torque:
Lower - 40 ft.lbs. (57Nm)
Upper Rear / Middle Bolts - 17 ft.lbs. (24 Nm)
= T
Lower Torsion Bar Bolt Torque: 17 ft.lbs. (24 Nm)
= T
Shock Bolt Torque: 30 ft.lbs. (43 Nm)
= T
Upper Carrier Bolt Torque: 50 ft.lbs. (71 Nm)
All Other Carrier Bolts: 35 ft.lbs. (50 Nm)
Apply anti-seize to splines

Polaris 2007 SPORTSMAN X2 800 Specifications

General

Brand	Polaris
Model	2007 SPORTSMAN X2 800
Category	Offroad Vehicle
Language	English