Type Iii Transmission Installation - Polaris Magnum 2x4 Service Manual

TRANSMISSION SERVICE
Type III, EZ .. Shift Transmission
Installation (Typical)
1. Install transmission from right side of ATV with output
shaft side down and input shaft side up toward right
rear corner of frame.
NOTE:
As you are guiding the output shaft into its mount-
ing, the rear drive chain can be installed onto shaft and
sprocket. Make sure chain is properly positioned on axle
sprocket.
2.
Loosely install lower mounting bolt and nut.
Be sure bolts are proper length or transmission damage
may occur.
3. Loosely install right side 3/8·16
x
3/4" mounting bolt
in top right hole.
4.
Attach washer, nut and roller chain guide to the right
side swing arm bolt.
5.
Align transmission case bushing with bolt and torque \
nut to 55 ft. Ibs. (7.6 kg-m). Bend the tab washer to
lock the bolt in place.
6. Loosely install left side 3/8·16
x
3/4/1 top mounting
bolt.
7. Install washer and nut on the left side swing arm bolt.
8. Align transmission case bushing with bolt and torque
nut to 55 ft. Ibs. (7.6 kg-m). Bend the tab washer to
lock the bolt in place.
9.
Align transmission with engine (See Clutch Section
for center distance and alignment procedure. Torque
lower mounting bolt to 25 ft. Ibs. (3.45 kg-m). Torque
right and left 3/8-16 x 3/4" bolts to 25 ft. Ibs. (3.45
kg-m).
10. Adjust torque stop by adjusting bolt until it contacts
the frame. Then tighten an additional one half turn
using a wrench. Hold the adjuster bolt and tighten the
jam nut.
11. Attach speedometer cable to angle drive and tighten.
12. Install skid plate and torque bolts to 5
ft.
Ibs. (.7
kg-m).
13.
Install driven clutch spacer and dust seal(s).
14.
Install inner cover and all PVT system components.
Refer to PVT Section for procedure.
10/96
8.16
Front
Nut
Bolt
Transmission Torque Stop Adjustment
Drive Key
Adapter (LH
Thread)
Drive
Ke~
\
01
~ \~~---
r<V) --
Angle~' ~~~­
Drive
8-10
ft. Ibs.
(1.10-1.38
kg-m)
Polaris Industries Inc.