2005 Polaris Sportsman 400/500 Service Manual, Page 232Get this manual
TRANSMISSION 20Install the oil baffle into the gearcase23Install the shift gear (16T) (G) on the shift drum shaftInstall the sector gear (F) in the bushing pocket on the left sideAligning the timing marks on the gearsF
Timing Marks
G 21Apply continuous bead of Crankcase Sealant (3Bond) (PN 2871557) to the LH gearcase mating surface and install the coverInstall and tighten the 22 screws in criss cross pattern to evenly secure the coverTorque the screws to 2734 ft.lbs(3746 Nm)
24Install the Oring (if not yet done) and lockout disc (H) onto the shift drum shaftBe sure to install the lockout disc (H) and detent star (J) with the raised edge facing outward