Transmission Installation - Polaris 2008 sportsman 800efi Service Manual

30. Install a new bellcrank onto the shift shaft. Note the keyed
spline on the bellcrank and shaft. Install the washer and nut.
Torque the bellcrank nut to specification.
Torque Bellcrank Nut:
12-18 ft.lbs. (16-24 Nm)
31. Install the shift switch. Install the retaining clip. Hook up
the switch harness and reconnect the lockout plunger
spring.
NOTE: Rotate the bellcrank to line the flat side of the
switch up to the flat side of the shaft.
32. Install transmission and add Polaris AGL Gearcase
Lubricant (PN 2873602) in the recommended amount.
Refer to Maintenance Chapter 2 for more information.
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SPORTSMAN TRANSMISSION

Transmission Installation

1. Install transmission from right side of vehicle.
2. Align output shafts to propshaft yokes and roll pin holes.
3. Slide output shafts into propshaft yokes and insert roll pins.
4. Position transmission in frame.
5. Loosely install left side and rear mounting brackets.
6. Loosely install lower right bracket bolt.
7. Loosely install front mounting bolts.
8. Install PVT back cover, bolts and driven clutch and torque
to specification.
IMPORTANT: Align clutches as outlined in Chapter 6
9. Tighten mounting fasteners in order A-F as shown.
Tighten Bolts in Sequence
C
B
E
Transmission Mounting Bolt Torque:
25 ft.lbs. (34.5 Nm)
10. Tighten rear gearcase fasteners to specification.
11. Install shift switch and shift rod.
12. Install remaining body panels and fasteners as required.
D
A
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