7
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
7.19
16. Install the upper shift fork and rotate the end into the
cam.
17. Install both rails and springs.
NOTICE
Make sure the spring is flush with the top of the shift
shaft rail. If not flush, the rail may not be fully seated.
18. Install the oil deflector plate and install new retaining
screws. Torque screws to specification.
TORQUE
Oil Deflector Plate Fasteners
8 ft-lbs (11 N·m)
19. Lubricate all seal lips to prevent damage upon
assembly.
20. Install the coupler input shaft assembly.
21. Install the rear output shaft assembly and silent
chain.
22. Lift up slightly on the rear output shaft and install the
front output shaft assembly.
23. If primary shaft was serviced, reinstall shaft
assembly into the transmission case.
24. Apply grease to the primary shaft and coupler input
shaft shim (s) (if found during removal), and place
them into the transmission cover for assembly.
25. Apply Crankcase Sealant (PN 2871557) to mating
surfaces.
26. Carefully install the transmission cover onto the
transmission. Apply even pressure to cover while
setting into place. A soft-faced hammer can be used
once the cover is started and aligned.
NOTICE
Take care not to damage seals during cover installation.
27. Install the retaining bolts and torque to specification.
TORQUE
Transmission Case Screws
20 ft-lbs (27 N·m)
28. Remove the old silicone material from the inner PVT
cover and transmission case using a wire brush.
Clean both surfaces thoroughly in preparation for
assembly.
29. Inspect the inner PVT cover. Replace if cracked or
damaged. The mating surface must be clean to
ensure adhesion of new silicone sealant.
30. Be sure to “flame treat” the inner PVT cover prior to
applying silicone to ensure good adhesion. Pass the
flame of a propane torch back and forth quickly over
the area where the silicone is to be applied (2-3
inches from the flame tip is recommended). Do not
hold the torch too close to the surface. Keep the
torch moving to prevent damage.
TRANSMISSION
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