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TRANSMISSION
Transmission Installation
1. Apply Polaris Premium All Season Grease (PN
2871423) to splines of front output shaft ,install new
O–ring in prop shaft.
2. With the help of an assistant, install transmission into
place from the rear of the frame, ensuring that the
output shaft and propshaft align and slide together.
3. Loosely install the bottom and front transmission-to-
frame screws and through-bolts.
4. Loosely install the upper transmission mount bracket
to the transmission and upper frame rail.
5. Reinstall the stabilizer bar assembly. Loosely install
the screws that secure the assembly to the frame, and
then the bolts/screws that attach the brackets to the
transmission.
6. Apply anti-seize to splines of rear drive shafts and
insert drive shafts into transmission. Install the upper
control arms into the transmission/stabilizer assembly
brackets to retain the rear suspension.
7. Install the stabilizer bar links and shocks into the
upper control arms.
8. Install PVT system. Refer to Chapter 6 PVT section
for procedures and torque specifications.
9. Install transmission vent line. Be sure vent line is not
kinked or pinched.
10. Reconnect the speed sensor and gear selection
switch connectors to the transmission.
11. Reconnect the shift rod.
12. Reinstall:
• Seat
• Side Panels
• Rear Rack/Rack Support
• Rear Cab Assembly
• Left/Right Foot Wells
8.8
Apply anti-seize to splines
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
13. Install the rear wheel nuts and torque to specification.
Rear Wheel Nut Torque
Refer to Chapter 2
14. With the ATV on level ground, add Polaris AGL Plus
Gearcase Lubricant to the proper level. See Chapter
2 for proper fill procedures and Torque Specifications.
Polaris AGL Plus Gearcase Lubricant
(PN 2878068) (12 oz.)
(PN 2878069) (Gallon)
Troubleshooting Checklist
Check the following items when shifting difficulty is
encountered.
• Idle speed adjustment
• Transmission oil type/quality
• Drive belt deflection
• *Worn, broken or damaged internal transmission
components
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Troubleshooting
