Specificiatons; Torque Specifications; Lubricant / Capacity; Transmission Service - Polaris 2008 sportsman 800efi Service Manual

SPORTSMAN TRANSMISSION

SPECIFICIATONS

Torque Specifications

Table 8-1: Torque Specifications
C
OMPONENT
Transmission Case Bolts
Oil Deflector Screws
Shift Cover Bolt
Bell Crank Nut
Trans. Drain/Fill Plug
Trans. Mounting Bolts
Snorkel Lock Screw
NOTE: TRANSMISSION ILLUSTRATIONS DEPICTED
WITH PARK LOCK. PARK LOCK IS REMOVED FOR
2007.

Lubricant / Capacity

Use only Polaris recommended products if possible.
Specified Lubricant:
Polaris AGL Gearcase Lubricant
(Gallon - PN 2873603) (12 oz. - PN 2873602)
Capacity: 15 oz. (450 ml)
Fill Plug Torque: 14 ft.lbs. (19 Nm)
Drain Plug Torque: 14 ft.lbs. (19 Nm)
8.6
. .
FT LBS
N
M
( . .)
IN LBS
27-34 37-46
(16-30) 2-3.3
6-12 8-16
12-18 16-24
14 19
25 34.5
8-12 11-16
=
= T

TRANSMISSION SERVICE

Transmission Removal

1. Disconnect linkage rod from gear selector handle.
2. Remove two bolts attaching gear selector mount to machine
frame.
3. Lift gear selector out of mounting bracket and away from
frame.
NOTE: TRANSMISSION ILLUSTRATIONS DEPICTED
WITH PARK LOCK. PARK LOCK IS REMOVED FOR
2007.
4. Remove seat, rear rack, rear cab, air box, exhaust system,
and right footwell (as required for access).
5. Disconnect transmission vent line.
6. Drain transmission lubricant.
7. Disconnect shift linkage rod end from transmission
bellcrank.
Linkage Rod
8. Disconnect gear position switch harness.
9. Remove auxiliary brake mounting bracket from frame and
secure out of way for transmission removal.
10. Remove PVT outer cover, both drive and driven clutch, and
inner PVT cover (refer to Clutch Chapter 6).
Transmission
Switch