Transmission Disassembly; Transmission Installation - Polaris SPORTSMAN 600 2003 Service Manual

TRANSMISSION REMOVAL CONT'D
9. Loosen or remove the bolts that secure the rear
gearcase. Move the rear gearcase back just
enough to slide the rear propshaft from the
transmission shaft.
Remove or Loosen
Rear Gearcase Bolts
10. Remove the park lock spring.
11. Remove left side transmission bracket, rear
bracket, and lower right bracket bolt.
12. Remove front transmission-to-engine mount
bolts. See illustration.
13. Remove transmission from right side of frame.

TRANSMISSION INSTALLATION

1. Install transmission from right side of vehicle.
2. Align rear output shaft to rear propshaft yoke and
roll pin hole.
3. Slide rear output shaft into propshaft yoke.
4. Position transmission in frame.
5. Install front propshaft and roll pin.
Park Lock Spring
6. Loosely install left side and rear mounting brackets.
7. Loosely install lower right bracket bolt.
8. Loosely install front mounting bolts.
9. Tighten mounting fasteners in order A-F as shown.
NOTE: Align clutches as outlined in Clutch Chapter 6.
Transmission Mounting
Bolts Torque
25 ft. lbs. (34.5 Nm)
D
C
F
E
Tighten Bolts In Sequence A through F

TRANSMISSION DISASSEMBLY

1. Place the bellcrank in neutral position.
Shift Shaft
Cover
NO TAG
Detent Pawl
Bellcrank
2. Remove the nut, and washer that secure the bell
crank. Remove the bellcrank.
TRANSMISSION TRANSMISSION
B
A
Case
8.5