Gear Shift Selector Assembly - Polaris SPORTSMAN 400 2003 Service Manual

4. Remove the three springs from gear shift
selector.
5. Slowly tilt gear shift selector body sideways to
drain oil.
NOTE: Do not tip gear shift selector body upside
down or detent bullets and stop pin may fall out.
Check for signs of moisture in the selector body.
7. Remove the two slides, one at a time.
NOTE: The LH (low) slide has two short notches and
the RH (high/rev) slide has one short and one long
notch. The slides must be replaced in the proper
channels.
8. Inspect O-rings for damage.
damage is found.
9. Flush housing with parts washer fluid or
penetrating oil to remove all moisture.
10. Dry all gear shift selector parts and remove any
corrosion with a wire brush.
Cap
Knob
Clamp
Boot
Cover (Apply
Loctitet 515)
Plastic
Sphere
Groove
Pin
Dowel
Pin
Detent
Spring
Low
Detent
2 Short
Bullet
Notches
Replace if any
Screw
Handle
Centering Spring
Detent Spring
Detent
Bullet
High/Reverse
(1 Short,
1 Long Notch)
Selector Slides
Inspect shift boot closely if moisture is present in
selector box.
6. Tap gear shift selector body, top down, against a
hard, smooth, flat surface to jar the dowel pin and
two detent bullets loose. Pull the detent bullets
and the dowel pin out of the gear shift selector
body.
GEAR SHIFT SELECTOR
ASSEMBLY
1. Insert slides into gear shift selector body, taking
care not to cut or tear O-rings in the process.
NOTE: The LH slide has two short notches and the
RH side has one short and one long notch. The slides
must be replaced in the proper channels for the shifter
to function properly.
2. Replace detent bullets, dowel pin, and springs by
reversing Steps 5 - 7 of Gear Shift Selector
Disassembly.
3. Clamp gear shift selector body lightly in a soft
jawed vise.
TRANSMISSION
8.3