Polaris 2005 SPORTSMAN 500 Servise Manual page 233

20. Install the oil baffle into the gearcase.
21. Apply a continuous bead of Crankcase Sealant
(3--Bond) (PN 2871557) to the LH gearcase
mating surface and install the cover. Install and
tighten the 22 screws in a criss cross pattern to
evenly secure the cover. Torque the screws to
27--34 ft.lbs. (37--46 Nm).
Cover Bolts -- 27--34 ft.lbs.
22. Place a small amount of grease (PN 2871551)
into the pocket before installing the sector gear
(F).
Apply Grease
23. Install the shift gear (16T) (G) on the shift drum
shaft. Install the sector gear (F) in the bushing
pocket on the left side. Aligning the timing marks
on the gears.
F
Timing Marks
24. Install the O--ring (if not yet done) and lockout disc
(H) onto the shift drum shaft. Be sure to install the
lockout disc (H) and detent star (J) with the raised
edge facing outward.
25. Install the detent pawl (I) onto the shift shaft. Install
the detent star (J). Install a new O--ring onto the
shift shaft. Apply a small amount of grease onto the
O--rings and end of the shift drum.
O--ring
I
TRANSMISSION
G
H
J
8.19