Assembly - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

Assembly

1. Inspect PVT inner cover-to engine seal. Replace if
cracked or damaged.
2. Place a new foam seal on transmission input shaft.
3. Apply RTV silicone sealant to outside edge of inner
cover-to-engine seal, to ensure a water tight fit
between the seal and the cover. Surfaces must be
clean to ensure adhesion of silicone sealant.
4. Reinstall cover and tighten rear cover bolts just
enough to hold it in place.
5. Fit lip of inner cover seal (A) to engine. Install seal
retainer plate and tighten screws securely.
6. Torque rear inner cover bolts (B) to specification.
7. Install clutch alignment washer (s) on transmission
8. Clean splines inside driven clutch and on the
9. Apply a light film of grease to the splines on the
10. Install the driven clutch, washer, lock washer, and
11. Clean end of taper on crankshaft and the taper bore
12. Install drive clutch and torque retaining bolt to
13. Reinstall drive belt noting direction of rotation. If a
14. Replace PVT outer clutch cover rubber gasket.
15. Reinstall PVT outer clutch cover and secure with
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
input shaft.
transmission input shaft.
shaft.
retaining bolt. Torque to specification.
inside drive clutch.
specification.
new belt is installed, install so numbers can be easily
read.
screws. Torque to specification.
CLUTCHING
6
6.9