Assembly - Polaris 2007 SPORTSMAN X2 800 Service Manual

SPORTSMAN TRANSMISSION
28. Remove the shafts as an assembly.
29. Remove the silent chain from the assembly for shaft
inspection.
Note location of hubs
30. Clean all components in a parts washer and inspect for
wear.
31. Inspect engagement dogs of gears and replace if edges are
rounded.
32. Inspect gear teeth for wear, cracks, chips or broken teeth.
Note the location of the hubs on the gear.
33. Remove seals from transmission case.
IMPORTANT: New seals should be installed after the
transmission is completely assembled.
34. Inspect bearings for smooth operation. Check for excessive
play between inner and outer race.
8.12

Assembly

1. Reinstall the chain onto the front output shaft and rear
output shaft.
2. Install front and rear output shafts into the case.
3. Before installing the cover make sure the sealing surfaces
are clean and dry, and shafts are fully seated in the
transmission case. Apply Crankcase Sealant (PN 2871557)
to the mating surfaces.
Apply Crankcase Sealant to mating surfaces.