Transmission Disassembly - Polaris 2007 Sportsman 500 EF Service Manual

Transmission Disassembly

1. Place the transmission in the Neutral gear before
disassembly.
2. Drain and properly dispose of transmission oil. See Chapter
2.
3. Remove the bellcrank nut (1) and remove the bellcrank (2).
4. Remove the c-clip (3) that holds the gear selector switch (4)
onto the shaft and remove the selector switch.
2
1
5. Remove the sector cover bolts (5) and remove the sector
cover (6). Removal can be aided by using your thumbs to
press down on the shafts and pulling up the cover with your
fingers.
5
6.
4
3
7.
8.
9.
NOTE: Note the timing marks on the shift gears (12,13)
for reassembly.
6
GENERAL INFORMATION
Remove the compression spring (7).
Remove the detent star (8). Note how the detent star fits
onto the splined shaft and the raised edge facing outward
for reassembly.
Remove the lockout disc (9). Note the raised edge facing
outward for reassembly.
Remove the shift shaft (10) and the shift gears (11,12).
12
11
10
7
13
7
9 8
8
8.9