8.22
TRANSMISSION
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
10. Apply a continuous bead of Crankcase 3 Bond
Sealant (PN 2871557) to the LH gearcase mating
surface and install the cover. Install and tighten the 20
screws in an even criss-cross pattern to evenly secure
the cover. Torque the screws to specification.
11. Install all new seals into the gearcases. Use the Rear
Output Seal Driver
(PN 2871698) and Rear Driveshaft
Seal Guide (PN 2871699) to install the seals into the
gearcase halves (refer to the following illustration to
identify the seals needing replacement).
12. Thoroughly clean the shift shaft housing. Be
sure the
transmission is in Reverse prior to reassembly.
13. Install the sector gear (16T) onto the shift drum shaft.
In
stall the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
timing marks on the gears as shown.
14. Install the lockout disc onto
the shift drum shaft. Be
sure to install the lockout disc with the raised edge
facing outward.
Gearcase Cover Bolts:
25-30 ft. lbs. (34-41 Nm)
Reverse Gear Shown
Timing Marks
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