Polaris General 2020

7
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
7.1
CHAPTER 7
TRANSMISSION
GENERAL INFORMATION - TRANSMISSION .. . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .. 7.2
SERVICE NOTES - TRANSMISSION . . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . 7.2
SPECIAL TOOLS - TRANSMISSION .. . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . 7.2
SERVICE SPECIFICATIONS - TRANSMISSION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 7.2
SHIFT CABLE SERVICE . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . 7.3
SHIFT LEVER / CABLE ASSEMBLY VIEW - GENERAL . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .. 7.3
SHIFT CABLE ROUTING - GENERAL .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .. 7.4
SHIFT LEVER / CABLE ASSEMBLY VIEW - GENERAL 4. .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .. 7.6
SHIFT CABLE ROUTING - GENERAL 4.. . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . . 7.7
SHIFT LEVER REPLACEMENT. ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... 7.9
SHIFT CABLE INSPECTION. .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... 7.9
SHIFT CABLE ADJUSTMENT . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . . 7.9
ASSEMBLY VIEWS - TRANSMISSION . . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . .. 7.11
TRANSMISSION ASSEMBLY VIEW . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . .. 7.11
TRANSMISSION MOUNTING TORQUE VALUES . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..7.12
TRANSMISSION VENT LINE .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . .7.13
TRANSMISSION VENT LINE ROUTING . . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .7.13
VENT LINE TERMINATION FITTING.. . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. .7.14
TRANSMISSION SERVICE . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . .7.15
TRANSMISSION REMOVAL .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . ..7.15
DIFFERENTIAL OPERATION . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . .7.19
TRANSMISSION DISASSEMBLY . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... .7.21
GEAR CLUSTER DISASSEMBLY . . ... . . .. . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..7.25
SNORKEL SHAFT REMOVAL / DISASSEMBLY . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .7.25
BEVEL DIFFERENTIAL DISASSEMBLY . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . .7.27
BEVEL DIFFERENTIAL ASSEMBLY . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .7.28
GEAR / SHAFT / BEARING INSPECTION . . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..7.30
TRANSMISSION ASSEMBLY . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .7.33
TRANSMISSION INSTALLATION . . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..7.38
TRANSMISSION