Torque Specifications; Special Tools; Gear Shift Selector Removal; Gear Shift Selector Disassembly - Polaris SPORTSMAN 400 2003 Service Manual

TRANSMISSION

TORQUE SPECIFICATIONS

COMPONENT
Transmission Case Bolts
Bell Crank Nut
Transmission Drain Plug
Transmission Mounting
Bolts

SPECIAL TOOLS

PART NUMBER
2871701 (Part of 2871702 Kit)
2871697 (Part of 2871702 Kit)
2871695 (Part of 2871702 Kit)
2871698 (Part of 2871702 Kit)
2871699 (Part of 2871702 Kit)
2871282
LUBRICATION
Refer to maintenance section for transmission
lubricant type and capacity.
GEAR SHIFT SELECTOR
REMOVAL
NOTE: To change fluid, remove selector box
assembly, disassemble, clean, and assemble.
1. Remove parts that interfere with access to shift
selector (seat, right side panel, and exhaust heat
shield, etc.).
2. Disconnect the two linkage rods from gear shift
selector slides.
3. Remove five bolts attaching gear shift selector to
the mounting bracket.
8.2
FT. LBS. NM
(IN.LBS.)
12 16.6
12 16.6
14 19
25 34.5
TOOL
DESCRIPTION
2 1/8 inch Wrench
Center Drive
Bushing Tool
Backlash Setting
Tool
Rear Output Seal
Driver
Rear Driveshaft
Seal Guide
Bearing Seal
Driver (50 mm)
4. Lift gear selector out of mounting bracket and
away from frame.
GEAR SHIFT SELECTOR
DISASSEMBLY
CAUTION:
Wear eye protection during this procedure. Read
each step completely before proceeding. Essential
parts may be lost or damaged if you do not heed this
caution!
1. Clamp gear selector body lightly in a soft jawed
vice. Using a cross pattern, loosen each of the
four screws holding the gear shift selector cover
to the gear shift selector body. Loosen each
screw only a few turns, then proceed to another
screw.
NOTE: These parts are under pressure from the
internal springs.
2. Carefully pull the gear shift selector cover and rod
from the gear shift selector body.
3. Set the cover/rod assembly aside.