8
8.7
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Transmission Removal
1. Place vehicle in “park”. Raise and securely support
rear of ATV under the frame. Remove both rear
wheels.
2. Disconnect the BLACK (negative) battery cable from
the battery.
3. Remove:
• Seat
• Side Panels
• Rear Rack/Rack Support
• Rear Cab Assembly
• Left/Right Foot Wells
4. Disconnect the vehicle speed sensor and gear
selection switch connectors from the transmission.
5. Disconnect transmission vent hose from the nozzle.
6. Disconnect shift rod end from transmission bellcrank.
7. Remove PVT outer cover, drive and driven clutches,
and the inner PVT cover. (refer to Clutch Removal in
Chapter 6).
8. Remove fasteners securing upper control arms to
stabilizer brackets and transmission brackets.
9. Remove the stabilizer bar links from the upper
control arms. Remove lower shock-to-control arm
fasteners.
10. Remove both rear drive shafts from transmission.
11. Remove the fasteners securing the stabilizer
assembly to the upper frame.
12. Remove the two mounting bolts that secure the front
of the transmission to the frame.
13. Remove all lower transmission mounting fasteners
from each side.
14. Remove the upper transmission support bracket
completely from the ATV.
15. With the help of an assistant, lift and remove
transmission out of rear of frame while pulling the
output shaft from the propshaft yoke.
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, install transmission into
place from the rear of the frame, ensuring that the
output shaft and propshaft align and slide together.
3. Loosely install the bottom and front transmission-to-
frame screws and through-bolts.
4. Loosely install the upper transmission mount bracket
to the transmission and upper frame rail.
5. Reinstall the stabilizer bar assembly. Loosely install
the screws that secure the assembly to the frame,
and then the bolts/screws that attach the brackets to
the transmission.
6. Apply anti-seize to splines of rear drive shafts and
insert drive shafts into transmission. Install the upper
control arms into the transmission/stabilizer
assembly brackets to retain the rear suspension.
7. Install the stabilizer bar links and shocks into the
upper control arms.
8. Install PVT system. Refer to Chapter 6 PVT section
for procedures and torque specifications.
9. Install transmission vent line. Be sure vent line is not
kinked or pinched.
10. Reconnect the speed sensor and gear selection
switch connectors to the transmission.
11. Reconnect the shift rod.
TRANSMISSION
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