Transmission Removal - Polaris SPORTSMAN 600 2003 Service Manual

TRANSMISSION TRANSMISSION
TORQUE SPECIFICATIONS
Transmission Case Bolts 27--34 ft. lbs. (37--46 Nm)
Bell Crank Nut . . . . . . . . .
Transmission Drain Plug 14--18 ft. lbs. (19--24 Nm)
Transmission Mount Bolts
Park Lockout Plunger . . .
Shift Cover Bolt Torque . .
LUBRICATION
Refer to maintenance section for transmission
lubricant type and capacity.
GEAR SELECTOR 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.

TRANSMISSION REMOVAL

1. Remove seat, rear rack, rear cab, air box, and
exhaust system, and right footwell (if required for
access).
Transmission
Front
2. Disconnect transmission vent line.
3. Drain transmission lubricant.
8.4
12--18 ft. lbs. (16--24 Nm)
. . 25 ft. lbs. (34.5 Nm)
14--18 ft. lbs. (19--24 Nm)
6--12 ft. lbs. (12--16 Nm)
4. Disconnect shift linkage rod end from transmission
bellcrank.
Linkage Rod
Transmission
Switch
5. Disconnect gear position switch harness.
6. Remove auxiliary brake mounting bracket from
frame and secure out of way for transmission
removal.
7. Remove PVT outer cover, both drive and driven
clutch, and inner PVT cover (refer to Clutch
Chapter 6).
8. Use the Roll Pin Removal Tool (PN 2872608) to
remove the roll pins from the front prop shaft and
the rear prop shaft. Remove the front propshaft.
Remove
Roll Pin