Polaris sportsman transmission removal and disassembly without pulling the engine

Introduction

This tutorial provides a step-by-step guide on how to remove and disassemble the transmission of a Polaris Sportsman 550 without pulling the engine. The process is similar for the Sportsman and Scrambler 850 and 1000 cc models, making it relevant for a variety of Polaris ATV owners.

Step 1: Gather Necessary Tools and Materials

Before starting the transmission removal process, ensure you have the following tools and materials ready:

• Homemade puller: A piece of all-thread, approximately one foot long, 3/4 inch in diameter, with fine threads (16 threads per inch).
• Basic hand tools: Wrenches, sockets, screwdrivers, and pliers.
• Safety gear: Gloves and safety glasses to protect yourself during the process.

Step 2: Prepare the ATV

• Use a flat, stable surface to work on your ATV.
• Ensure the ATV is turned off and has cooled down completely.
• Disconnect the battery to prevent any electrical issues during the disassembly.

Step 3: Access the Transmission

• Remove any body panels or covers that obstruct access to the transmission.
• Take note of any screws or fasteners removed for reassembly later.

Step 4: Remove the Drive Belt

• Locate the drive belt cover and remove it.
• Carefully take out the drive belt by loosening the tension and sliding it off the clutch.

Step 5: Detach the Transmission

• Locate the transmission mounting bolts and remove them using the appropriate socket.
• Be careful to support the transmission as you remove the last bolts to avoid dropping it.

Step 6: Use the Homemade Puller

• Position your homemade puller over the transmission component that needs to be removed.
• Ensure it is securely attached, then slowly tighten the puller to extract the transmission part.

Step 7: Disassemble the Transmission

• Once the transmission is free, place it on a clean workbench.
• Carefully remove any additional components, such as gears or shafts, noting their order for reassembly.
• Inspect parts for wear and damage during disassembly, which can help in deciding what to replace.

Conclusion

You have successfully removed and disassembled the transmission from a Polaris Sportsman 550 without pulling the engine. Be sure to document your steps and take care while handling the components. If any parts are worn or damaged, consider replacing them before reassembly. For further guidance, you can refer to the internal transmission video for the Sportsman 1000 linked in the description. Happy repairing!