Polaris Sportsman 800 EFI 4x4 2012 Service Manual page 376

TRANSMISSION
17. Replace and grease the O-rings on the shift drum
before installation.
18. Install the shift drum into the case.
NOTE: Make sure shift shaft pins are properly
positioned in the slot on selector arms.
19. Lift the shift rail slightly and rotate the rail/fork
assembly so it meshes with the tracks on the
shiftdrum. Be sure the wave springs are properly in
place and that the shift rail is seated into the pocket
on the backside of the case.
20. Install the helical gear and bearing onto the pinion
shaft.
8.36
21. Clean the mating surfaces of the case and cover.
Apply Crankcase Sealant (PN 2871557) to the
mating surfaces. Be sure the locating pins (knock
pipes) are in place. Reinstall cover, LH mounting
bracket and torque bolts in a criss-cross pattern in 3
steps to specification.
22. Grease the seal lips of the input shaft seal. Apply
electricians tape or somehow cover the splines of the
shaft to protect the seal lips during installation. Install
new input shaft seal.
23. Install drain plug with a new sealing washer. Torque
drain plug to specification.
24. Place a small amount of grease (PN 2871551) into
the pocket before installing the sector gear. Install
the shift gear (16T) on the shift drum shaft. Install the
sector gear in the bushing pocket on the left side.
Aligning the timing marks on the gears.
NOTE: Note the location of the skip tooth on the
splines. Apply a light coating of grease on the
gear teeth.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Cover Bolt Torque:
27-34 ft-lbs (36.5-46 Nm)