Gear Shift Selector Removal; Gear Shift Selector Disassembly - Polaris 2004-2005 Sportsman 6x6 Service Manual

TRANSMISSION
SPECIAL TOOLS
PART NUMBER
2871710
Torque Specifications
Transmission Case Bolts
Bell Crank Nut . . . . . . . . . . . . . .
Transmission Drain Plug
Speedometer Angle Drive
Transmission Mounting Bolts
Drive Sprocket Bolt . . . . . . . . . .
Output Shaft Bearing
Mounting Nuts . . . . . . . . . . . . . .
Swing Arm Pivot Bolts . . . .
LUBRICATION
NOTE: Refer to maintenance
transmission lubricant type and capacity.
GEAR SHIFT SELECTOR
REMOVAL
NOTE: To change fluid, remove selector box
assembly, disassemble, clean, and assemble.
1. Remove parts that interfere with access to shift
selector (seat, right side panel, and exhaust heat
shield, etc.).
2. Disconnect the two linkage rods from gear shift
selector slides.
3. Remove five bolts attaching gear shift selector to
the mounting bracket.
4. Lift gear selector out of mounting bracket and
away from frame.
GEAR SHIFT SELECTOR
DISASSEMBLY
CAUTION:
Wear eye protection during this procedure. Read
each step completely before proceeding. Essential
parts may be lost or damaged if you do not heed this
caution!
8.2
TOOL
DESCRIPTION
10" Center
Distance Tool
. . . . . 12 ft. lbs. (16.6 Nm)
12 ft. lbs. (16.6 Nm)
. . . . . 14 ft. lbs. (19.3 Nm)
. . . . 11 ft. lbs. (15 Nm)
. . 25 ft. lbs. (34.5 Nm)
17 ft. lbs. (23.5 Nm)
12 ft. lbs. (16.6 Nm)
150 ft. lbs. (207.5 Nm)
section for
1. Clamp gear selector body lightly in a soft jawed
vice. Using a cross pattern, loosen each of the
four screws holding the gear shift selector cover
to the gear shift selector body. Loosen each
screw only a few turns, then proceed to another
screw.
NOTE: These parts are under pressure from the
internal springs.
2. Carefully pull the gear shift selector cover and rod
from the gear shift selector body.
3. Set the cover/rod assembly aside.
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.
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