Polaris 2008 sportsman 800efi Service Manual page 260

SPORTSMAN TRANSMISSION
24. Place a small amount of grease (PN 2871551) into the
pocket before installing the sector gear. Install the shift gear
(16T) on the shift drum shaft. Install the sector gear in the
bushing pocket on the left side. Aligning the timing marks
on the gears.
NOTE: Note the location of the skip tooth on the
splines. Apply a light coating of grease on the gear
teeth.
25. Install the shift shaft and the detent star. Note the keyed
spline on the end of the shaft.
26. Install the detent pawl and spring. Install a new o-ring onto
the shift shaft after the detent pawl is assembled to the shaft.
Place a small amount of grease on the small o-ring on the
shift shaft and on the detent star. Grease the o-ring on the
end of the shift drum.
8.16
27. Apply Crankcase Sealant (PN 2871557) onto the cover and
case mating surfaces. Install the cover and hand tighten all
of the bolts.
Install Cover Bolts
28. Tighten bottom left corner bolt first. This helps to align the
cover and shafts to ensure smoother and precise shifting.
Torque the bolt to specification.
Tighten First
29. Torque the remaining bolts to specification.
Cover Bolt Torque:
6-12 ft.lbs. (12-16 Nm)
= T