Gear Shift Selector Installation; Boot Replacement - Polaris SPORTSMAN 400 2003 Service Manual

TRANSMISSION
4. Fill selector body with Polaris 0W-40 All Season
Synthetic motor oil. The oil level should be at one
half the height of the slides (approx. 1 oz.).
Gear Shift Selector Capacity: 1 oz.
Polaris 0W-40 All Season Synthetic Oil
(PN 2871281) - Quart
(PN 2871844) - Gallon
CAUTION: Too much oil could cause the selector to
hydrolock. Be sure the selector box is level when
adding oil.
5. Wipe gear selector dry, clean surfaces of cover
and selector box with Loctitet Primer T and place
a bead of Loctitet 518 Gasket Eliminator or
Crankcase Sealant (PN 2871557) completely
around the edge of the gear shift selector body.
6. Carefully reattach cover/rod assembly to gear
shift selector body.
neutral, or butterfly may be damaged.
7. Torque cover screws to 12 ft. lbs. (17 Nm).
GEAR SHIFT SELECTOR
INSTALLATION
1. Place gear shift selector back into the mounting
bracket and replace five bolts.
2. Reconnect linkage rods to gear shift selector
slides. Adjust as required.
adjustment procedures.
3. Replace remaining parts.
8.4
Make sure slides are in
See linkage

BOOT REPLACEMENT

NOTE: If moisture is found in the gear shift selector
the boot should be replaced.
Cap
Screw
Knob
Clamp
Seal with
RTV silicone
Boot
1. Using a slotted screwdriver, remove cap from
gear shift knob.
2. Remove torx screw securing knob to selector rod.
3. Pull selector knob off selector rod.
4. Remove band clamp on rubber boot.
5. Slide boot off selector rod and replace with a new
one.
6. Apply RTV silicone to selector rod to seal top of
boot.
7. Place band clamp in position and tighten using CV
boot clamp pliers.
8. Replace shift knob, securing it to selector rod with
screw removed in Step 2.
9. Push shift knob cover back into place. Allow
approximately 12 hours for RTV silicone to cure.