Type Iii Transmission Disassembly - Polaris Magnum 2x4 Service Manual

TRANSMISSION SERVICE
Type III, EZ .. Shift Transmission
Disassembly (Typical)
1 . Remove speedometer angle drive, sprocket
retaining circlip and sprocket.,
2. Remove the transmission cover bolts.
3. With a soft face hammer tap on the cover bosses
and carefully walk the cover off. See III. 1.
4. Using the battery cable clamp puller, remove the
bearing from the sliding gear shaft. See III. 2.
5. Remove outer thrust washer.
6. To remove the needle bearing from the low gear, tip
transmission to point end of shaft downward. Work
gear back and forth as shown until bearing is
exposed and slide bearing out. See III. 3.
7. Remove the low gear and inner thrust washer.
8. Place a 1/2" wrench on each of the transmission bell
crank retaining nuts to aid in removing the shift fork
shaft.
NOTE: Transmission must be in neutral to remove shift
forks.
9. Remove the low range shift fork shaft with
engagement dog by rotating the low gear shift arm
clockwise and pulling outward on shift fork shaft.
1 O. Remove output shaft and gear assembly by tapping
on shaft with a soft faced hammer, from the back
side of the gear case assembly.
11. Remove sliding gear shaft with high/reverse shift
shaft and input shaft assembly as a unit by gradually
walking assemblies from their bearing mounts while
rotating the high/reverse shift arm counterclockwise.
NOTE: Make sure input shaft gear clears oil deflector, but
do not remove the oil deflector. See assembly photo at
top of next page.
7/96
8.14
Tap with soft
face\;r
o
Tap with soft
~
face hammer
III. 1
Tap with soft
face hammer
/
o
Bearing
III. 2
III. 3
Work gear back
and forth until bearing
is exposed
Polaris Industries Inc.