8.8
TRANSMISSION
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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, install
transmission into
place from the rear of the frame, ensuring that the
output shaft and propshaft align and slide together.
3. Loosely install the bottom and front transmission-to-
fra
me screws and through-bolts.
4. Loosely install the upper transmission mount bracket
to the tra
nsmission and upper frame rail.
5. Reinstall the stabilizer bar ass
embly. Loosely install
the screws that secure the assembly to the frame, and
then the bolts/screws that attach the brackets to the
transmission.
6. Apply anti-seize to splines of rear drive shafts and
in
sert drive shafts into transmission. Install the upper
control arms into the transmission/stabilizer assembly
brackets to retain the rear suspension.
7. Install the stabilizer bar
links and shocks into the
upper control arms.
8. Install PVT system. Refer to
Chapter 6 PVT section
for procedures and torque specifications.
9. Install transmission vent line. Be sure vent line is not
kinked
or pinched.
10. Reconnect the speed sensor
and gear selection
switch connectors to the transmission.
11. Reconnect the shift rod.
12. Reinstall:
•Seat
• Side Panels
• Rear Rack/Rack Support
• Rear Cab Assembly
• Left/Right Foot Wells
13. Install the rear wheel nuts and torque to specification.
14. With the ATV on level ground, add Polaris AGL Plus
Gea
rcase Lubricant to the proper level. See Chapter
2 for proper fill procedures and Torque Specifications.
Troubleshooting Checklist
Check the following items when shifting difficulty is
encountered.
• Idle speed adjustment
• Transmission oil type/quality
• Drive belt deflection
• *Worn, broken or damaged internal transmission
comp
onents
Apply anti-seize to splines
Rear Wheel Nut Torque
Refer to Chapter 2
Polaris AGL Plus Gearcase Lubricant
(PN 2878068) (12 oz.)
(PN 2878069) (Gallon)
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