Polaris 2005 SPORTSMAN 500 Servise Manual page 231

12. Inspect the shift drum for any damage or wear.
Inspect the splines of the shift drum. Replace the
O--rings on the end of the shift drum and lubricate
them before assembly.
13. Stretch the silent chain on a flat surface and
measure the length of 8 pitches in a minimum of
three places on the chain. Replace the chain if the
measurement is longer than 3.0904" (7.8496
cm).
Silent Chain Length:
3.0904" (7.8496 cm)
14. The shift drum (C), reverse shaft (D), input shaft
(E), and output gear assembly must be installed
at the same time to properly align all components.
E
D
NOTE: To ease assembly use a plastic tie strap
to hold the shift forks (D) and the shift drum (C)
together during assembly.
15. With the gearcase on it's side, hold the gear
cluster assembly and output assembly together.
Carefully install each shaft into their respective
recess in the gearcase.
16. With all of the components in the correct positions
install the 4 output gear assembly screws. Apply
Loctitet 262 (PN 2871952) to the threads of the
screws. Torque the screws to 8--12 ft.lbs. (11--16
Nm). NOTE: If the transmission is in locked in
Park take it out of gear.
8--12 ft.lbs.
TRANSMISSION
C
D
8.17