Transmission Installation - Polaris 2008 sportsman 800efi Service Manual

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, rotate transmission into place
from the right side of the frame, aligning the forward
transmission bracket into the rear engine mounting holes
while ensuring that the output shaft and propshaft align and
slide together.
3. Loosely install lower transmission mounting fasteners and
forward engine mounting nuts.
4. Install the rear support bracket, middle support bracket and
torsion bar support bracket. Torque all lower bracket bolts
to specification. Torque all upper rear and middle support
bracket bolts (circled) to specification.
Transmission Bracket Bolt Torque:
Lower - 40 ft.lbs. (57Nm)
Upper Rear / Middle Bolts - 17 ft.lbs. (24 Nm)
5. Install the upper control arms. Refer to Chapter 5 for
procedures and torque specifications.
= T
X2 / Touring Transmission
6. Reconnect the torsion bar to both lower control arms.
Torque to specification.
Lower Torsion Bar Bolt Torque: 17 ft.lbs. (24 Nm)
7. Install both upper shock absorber mounts and torque to
specification.
Shock Bolt Torque: 30 ft.lbs. (43 Nm)
8. Apply anti-seize to splines of rear drive shafts and insert
drive shafts into carriers and transmission. Install rear
carriers and hubs.
Torque lower carrier bolts to specification. Torque all other
control arm bolts and remaining carrier bolts to
specification.
Upper Carrier Bolt Torque: 50 ft.lbs. (71 Nm)
All Other Carrier Bolts: 35 ft.lbs. (50 Nm)
= T
= T
Apply anti-seize to splines
= T
8.25
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