Transmission Disassembly - Polaris 2005 SPORTSMAN 500 Servise Manual

12. Install the park lock spring.
Park Lock Spring
13. Reconnect the gear position switch harness and
shift linkage rod.
Linkage Rod
Transmission
Switch
14. Install PVT system. Refer to Chapter 6 PVT
section for procedure.
15. Install airbox assembly and transmission vent
line. Be sure vent line is not kinked or pinched.
16. With the ATV on level ground and with the
transmission installed,
Gearcase Lubricant to the proper level. See Page
2.11 Chapter 2 for proper fill procedures.
Polaris AGL Gearcase Lubricant
(PN 2873602) (12 oz.)
(PN 2873603) (Gallon)
17. Install the rear wheel nuts and torque to
specification.
Auxiliary Brake
add Polaris AGL
Rear Wheel Retaining Bolt Torque
20 ft. lbs. (27 Nm)
TRANSMISSION
DISASSEMBLY
1. Place the transmission in the Neutral gear before
disassembly.
2. Remove the bellcrank nut and remove the
bellcrank.
3. Remove gear indicator switch.
Remove Bellcrank
4. Drain and properly dispose of transmission oil.
TRANSMISSION
Remove switch
8.7