Polaris 2004-2005 Sportsman 6x6 Service Manual page 34

MAINTENANCE
SHIFT LINKAGE
ADJUSTMENT
Linkage rod adjustment is necessary when
symptoms include:
G No All Wheel Drive light
G Noise on deceleration
G Inability to engage a gear
G Excessive gear clash (noise)
G Shift selectors moving out of desired range
NOTE: When adjusting linkage, always adjust both
linkage rods. The adjustment of one rod can prevent
proper adjustment of the other rod.
necessary components to gain access to shift linkage
rod ends (i.e. exhaust heat shield, exhaust pipe, etc.).
Gear Selector
Low Range
Slides
Jam
Jam Nut
Nut
NOTE: Rod end orientation, rod ends are
both down.
Ill. 1
1. Inspect shift linkage tie rod ends, clevis pins, and
pivot bushings and replace if worn or damaged.
Lubricate the tie rod ends with a light aerosol
lubricant or grease.
2. Loosen all rod end adjuster jam nuts see Ill. 1.
3. Note orientation of tie rod end studs with stud up
or down. Remove both rod end studs from
transmission bell cranks.
4. Be sure idle speed is adjusted properly.
NOTE: It is important to disconnect both rod ends
from the transmission bell cranks. If one linkage rod
is incorrectly adjusted, it can affect the adjustment of
the other rod.
2.14
5. Place gear selector in neutral. Make sure the
transmission bell cranks are engaged in the
neutral position detents.
Adjust to align linkage rod end studs
with holes in bellcrank(s).
Ill. 2
Remove 6. Be sure the shift linkage rod ends are firmly
attached to the gear selector slides. Adjust the
low range (inside) rod so the rod end is centered
on the transmission bell crank. Install the lock nut
to the rod end and torque to 35 in. lbs. (4 Nm).
Place
mark
on rod
Ill. 3
7. Rotate the linkage rod clockwise until resistance
is felt. Mark the rod so revolutions can be easily
counted. See Ill. 3 at right.
8. Rotate the linkage rod counterclockwise until the
same resistance is felt, counting the revolutions
as the rod is turned.
9. Turn the rod clockwise again one half of the
revolutions counted in Step 9.
10. Tighten the rod end jam nuts securely while
holding the rod end.
tightened with both front and rear rod ends
parallel to each other. If jam nuts are properly
tightened, the rod should rotate freely 1/4 turn
without binding.
11. Repeat Steps 7-10 for the High/Reverse rod.
35 in. lbs.
(4 Nm)
35 in. lbs.
(4 Nm)
S Rotate rod both directions to
find points where resistance
is felt.
S Center the rod between the
points.
S Hold rod end parallel to
mounting surface and
tighten jam nut.
Parallel
The jam nuts must be