8.6
SPORTSMAN TRANSMISSION
SPECIFICIATONS
Torque Specifications
NOTE: TRANSMISSION ILLUSTRATIONS DEPICTED
WITH PARK LOCK. PARK LOCK IS REMOVED FOR
2007.
Lubricant / Capacity
Use only Polaris recommended products if possible.
TRANSMISSION SERVICE
Transmission Removal
1. Disconnect linkage rod from gear selector handle.
2. Remove two bolts attaching gear selector mount to machine
frame.
3. Lift gear selector out of mounting bracket and away from
frame.
NOTE: TRANSMISSION ILLUSTRATIONS DEPICTED
WITH PARK LOCK. PARK LOCK IS REMOVED FOR
2007.
4. Remove seat, rear rack, rear cab, air box, exhaust system,
and right footwell (as required for access).
5. Disconnect transmission vent line.
6. Drain transmission lubricant.
7. Disconnect shift linkage rod end from transmission
bellcrank.
8. Disconnect gear position switch harness.
9. Remove auxiliary brake mounting bracket from frame and
secure out of way for transmission removal.
10. Remove PVT outer cover, both drive and driven clutch, and
inner PVT cover (refer to Clutch Chapter 6).
Table 8-1: Torque Specifications
COMPONENT
FT
.LBS.
(
IN.LBS.)
N
M
Transmission Case Bolts 27-34 37-46
Oil Deflector Screws (16-30) 2-3.3
Shift Cover Bolt 6-12 8-16
Bell Crank Nut 12-18 16-24
Trans. Drain/Fill Plug 14 19
Trans. Mounting Bolts 25 34.5
Snorkel Lock Screw 8-12 11-16
=
Specified Lubricant:
Polaris AGL Gearcase Lubricant
(Gallon - PN 2873603) (12 oz. - PN 2873602)
Capacity: 15 oz. (450 ml)
= T
Fill Plug Torque: 14 ft.lbs. (19 Nm)
Drain Plug Torque: 14 ft.lbs. (19 Nm)
Transmission
Switch
Linkage Rod
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