Polaris Sportsman 700 / 800 / 800 X2 EFI Service Manual (PN 9920378) – FINAL DRIVE

Page 1

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2

GEARCASE FLUID / CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2

FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

FRONT DRIVE SHAFT (CV) BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.4

REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4

FRONT HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6

PROP SHAFT - FRONT OR REAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7

U-JOINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.7

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.8

DRIVE AXLE EXPLODED VIEWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

DRIVE SHAFTS AND PROPSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10

FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS). . . . . . . . . . 7.11

EXPLODED VIEW (STANDARD MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.11

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12

GEARCASE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12

DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13

REASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.17

SETTING RING GEAR BACKLASH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18

FRONT GEARCASE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19

GEARCASE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20

FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS). . . . . . . . . 7.21

ADC GEARCASE EXPLODED VIEW (DELUXE MODELS). . . . . . . . . . . . . . . . . . . . . .7.21

OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.22

ADC COIL TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23

ADC DIFFERENTIAL HYDRAULIC CIRCUIT BLEEDING. . . . . . . . . . . . . . . . . . . . . . .7.23

DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23

ADC GEARCASE PISTON REPLACEMENT PROCEDURE. . . . . . . . . . . . . . . . . . . . . 7.27

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.29

REAR HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.32

DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.34

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.34

REAR DRIVE (CV) SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.35

SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.36

CV BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.37

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38

DRIVE SHAFT AND CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39

REAR GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.39

DISASSEMBLY AND INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.39

REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.42

REAR GEARCASE EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43

FINAL DRIVE

CHAPTER 7

FINAL DRIVE

7.1

Page 2

FINAL DRIVE

SPECIFICATIONS

Torque Table

OMPONENT

F/R Steel Wheel Nuts 30 41

F/R Aluminum Wheel Nuts 90 122

Front Hub Nut 70 95

Rear Hub Nut 80 109

Front Gearcase Mount Bolts 30 41

Standard Gearcase Screws 14 19

Rear Gearcase Mount Bolts 30 41

Rear Gearcase Bolts 25 34 Lower Hub Carrier Bolts 50 68 Upper Hub Carrier Bolts 35 48

ADC Pump Screws (17-23) 1.9 - 2.5 ADC Cover Screws 7 - 11 9.4 - 14.9 ADC Bleed Valves (80) 9

IMPORTANT: Verify which type of wheel ATV is equipped with (aluminum or steel) when torquing

wheel nuts.

.LBS.

(

IN.LBS.)

Gearcase Fluid / Capacity

GEARCASE DESCRIPTION

Centralized Hilliard

(Standard Models)

Centralized Hilliard

w/ ADC

(Deluxe Models)

ADC Gearcase

Pump Reservoir

Rear Gearcase

Demand Drive LT

Premium Hub Fluid

8.97 oz. (265 ml)

Demand Drive LT

Premium Hub Fluid

9.3 oz. (275 ml)

Polaris ADC or AW ISO 10

Hydraulic Fluid

AGL Synthetic or ADF

5.0 oz. (150 ml)

FRONT DRIVE AXLE

Removal

1. Set the ATV in park. Remove hub dust cap.

2. Remove cotter pin.

3. Loosen the hub retaining nut.

4. Loosen - but do not remove - the wheel nuts.

5. Safely lift and support the front of the ATV.

CAUTION

Special Tools

ART NUMBER TOOL DESCRIPTION

2872608 Roller Pin Removal Tool 8700226 CV Boot Clamp Pliers 2870772 1 3/4” Straight Wrench

PA-48542

Serious injury could occur if machine tips or falls.

6. Remove wheel.

7. Remove the two brake caliper attaching bolts.

ADC Gearcase Piston

Installation Tool

CAUTION

Do not hang the caliper by the brake line. Use wire

to hang the caliper to prevent possible da mage to

the brake line.

7.2

Page 3

FINAL DRIVE

8. Remove hub.

9. Remove cotter pin and nut from lower A-arm ball joint. Remove lower A-arm from ball joint.

10. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.

11. Pull strut assembly out while pivoting front drive shaft downward until it clears strut assembly.

7.3

Page 4

FINAL DRIVE

Installation

1. Install new spring ring on drive shaft. Apply an anti-seize compound to splines. Align splines of drive shaft with front gearcase and install by lightly tapping on drive shaft with rubber faced hammer.

2. Install drive shaft in strut.

3. Install lower ball joint, torque nut to specification and install new cotter pin.

= T

Ball Joint Retaining Nut Torque:

25 ft. lbs. (34.5 Nm)

FRONT DRIVE SHAFT (CV) BOOT

Inspection

Check the front and rear driveshaft CV boots for any tears or leaking grease. If the driveshaft boot loses all of the grease CV joint failure will occur.

Replacement

4. Install hub and tighten hub nut to specification.

= T

Front Hub Retaining Nut Torque:

70 ft. lbs. (95 Nm)

1. Remove wheel, brake caliper, and wheel hub. Refer to “FRONT DRIVE AXLE REMOVAL” earlier in this chapter for procedure.

2. Remove cotter pin and castle nut from A-arm ball joint.

7.4

Page 5

FINAL DRIVE

3. Disconnect A-arm from ball joint using a tie rod fork.

4. Slide strut off end of drive shaft and tie it up out of the way of the shaft.

5. Remove clamps from rubber boot using the proper boot clamp pliers.

6. Remove the large end of the boot from the CV joint, slide the boot back and separate the wheel spindle and CV joint assembly from the axle shaft by pulling the shaft sharply outward, away from the CV joint. It may be necessary to tap the CV joint assembly outward with a soft faced hammer.

Retaining Ring

7. Remove small clamp and boot from driveshaft.

NOTE: If the ATV has been operat ed wit h a da maged boot, the CV joint grease may be contaminated. Inspect the grease carefully for contamination, and clean the joint thoroughly if necessary. Front drive axle CV boot replacement requires 3.5 oz. of grease.

CV Joint Grease -3.5 oz.

(Refer to parts manual for boot kit)

CV Boot Clamp Pliers:

Earless Type: (PN 8700226)

Boot replacement with complete CV joint

cleaning requires the entire 3.5 oz. of grease.

8. Before installing the new boot, remove all grease from the boot area and shaft.

NOTE: It is very important to use the correct type and quantity of grease. Use only the grease contained in the boot kit. DO NOT use a substitute grease and DO NOT overfill or under fill the CV joint.

9. Slide the new clamp and boot (small end first ) over the splined shaft, then slide (tap) the CV joint into the splines of the axle.

10. Add grease through large end of boot.

11. Install a new boot onto the axle shaft and fill the CV joint and boot with the correct type and amount of grease.

12. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the shaft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of th e bo ot is in its correct location on the axle. CARE MUST BE TAKEN TO AVOID DAMAGE TO THE NEWLY INSTALLED BOOT.

Pull Shaft to Remove from CV Joint

7.5

Page 6

FINAL DRIVE

13. Install the small clamp on the boot.

Front Shaft

FRONT HUB

Disassembly

1. Remove outer snap ring.

punch in the reliefs as shown.

NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.

3. Inspect the bearing.

NOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feel. While rotating bearings by hand, inspect for rough spots, discoloration, or corrosion. The bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement sideways between inner and outer race.

4. Inspect bearing housing for scratches, wear or damage. Replace housing if damaged.

Assembly

2. From the back side, tap on the outer bearing race with a drift

7.6

1. Support bottom of hubstrut housing.

2. Start bearing in housing.

3. Press bearing into place until outer race bottoms on housing.

CAUTION

When using an arbor press be sure to press only on

the outer race to avoid bearing damage.

4. Install snap ring into groove.

Page 7

FINAL DRIVE

PROP SHAFT - FRONT OR REAR

Removal and Installation

1. Using Roll Pin Removal Tool (PN 2872608), rem ove the roll pin from prop shaft at rear of housing (front only) or transmission output shaft (rear only). Slide prop shaft back and away from housing, then pull sharply forward to remove from transmission shaft.

2. For installation, reverse the removal procedure.

U-JOINT

Disassembly

CAUTION

Always wear eye protection when working with

spring-tensioned components

1. Remove internal or external snap ring from all bearing caps.

NOTE: If removing rear propshaft, loosening and/or removal of rear gearcase mounting bolts may be required to gain necessary clearance for propshaft removal.

See “REAR GEARCASE” on page 7.39.

NOTE: If yoke or bearing is removed, cross bearing must be replaced. Note orientation of grease fitting (if equipped) and mark inner and outer yoke for correct re-positioning during installation.

2. Support inner yoke as shown and drive outer yoke down (bearing cap out) with a soft face hammer.

7.7

Page 8

FINAL DRIVE

3. Support U-joint in vise as shown and drive inner yoke down to remove remaining bearing ca

4. Force U-joint cross to one side and lift out of inner yoke.

Assembly

1. Install new bearing caps in yoke by hand. Carefully install U-joint cross with grease fitting properly positioned inward toward center of shaft. Take care not to dislod ge needle bearings upon installation of cross joint . Tighten vise to force bearing caps in.

2. Using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cros s as bearing caps using a suitable arbor, fully seat bearing cap in one side. Continually check for free movement of bearing cross as bearing caps are assembled. are assembled.

7.8

3. Install snap ring to contain bearing cap just installed. Repeat procedure for other side.

Page 9

4. Install snap ring to contain bearing cap just installed. Repeat procedure for other side.

5. Install snap ring to contain bearing cap just installed. Repeat procedure for other side.

6. Seat all bearing caps against snap rings by supporting cross shaft and tapping on each corner as shown.

FINAL DRIVE

7. When installation is complete, yo kes must pivot freely in all directions without binding. If the joint is stiff or binding, tap the yoke lightly to center the joint until it pivots freely in all directions.

7.9

Page 10

FINAL DRIVE

DRIVE AXLE EXPLODED VIEWS

Drive Shafts and Propshafts

NOTE: Refer to your parts manual for the proper replacement parts.

Drive Axle Components

Inner CV Joint

Circlip

Inner Boot

Clamps

Outer Boot

Drive Boot Replacement Kits

Circlip

Outer CV Joint

Outer Clamp

Propshaft Assy.

Yoke, Front Gearcase

Boot

Prop Shaft Components

Cross & Bearing Kit

Clamp

3.5 oz. grease

O-Ring

Prop Shaft

Yoke, Prop to Transmission

7.10

Yoke, Rear Gearcase

Prop Shaft

Yoke, Prop to Transmission

Page 11

FINAL DRIVE

FRONT GEARCASE - CENTRALIZED HILLIARD (STANDARD MODELS)

Exploded View (Sta ndard Models)

Ref. # Description Qty Ref. # Description Qty

1 Bolt 8 12 Vent Tube 1 2 Oil Seal 1 13 Plug 1 3 Input Cover Plate Asm. 1 14 Gearcase Sub Asm. 1 4 O-Ring 1 15 Ring Gear / Clutch Housing 1 5 Retaining Ring 1 16 Output Hub Asm. 2 6 Bearing 3 17 Roll Cage Asm 1 7 Pinion Gear Asm. 1 18 Armature Plate 1 8 Pinion Bushing 1 19 Output Cover Asm 1

9 Magnetic Drain Plug 1 20 Connector Asm. 1 10 Oil Seal 2 21 Thrust Button Asm. 1 11 Plug Cap 1 22 Set Screw 1

7.11

Page 12

FINAL DRIVE

Operation

Engaging front gearcase: The A WD swit ch may be turned on or off while the vehicle is moving. AWD will not enable until the engine rpm is below 3100 RPM. Once enabled, the AWD remains engaged while the front gearcase is moving and will not disengage until the rear wheels regain traction.

Engage the AWD switch before getting into conditions where the front wheel drive may be needed. If the rear wheels are spinning , release the throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are

spinning may cause severe drive shaft and

gearcase damage. Always switch to AWD while the

rear wheels have traction or are at rest.

With the A WD switch off the vehicle drives only the rear wheels (2 wheel drive). When the AWD switch is activated it engages the hilliard, locking both front axles into all wheel drive when there is a loss of rear wheel traction.

Roll Cage

Output Hubs

Armature Plate

Rollers

Ring Gear

Roll Cage

CAUTION

If the rear wheels are spinning, release the throttle

before turning the AWD switch on. If AWD is

engaged while the wheels are spinning, severe

drive shaft and clutch damage could result.

Disengagement: As the front and rear wheels gain equal traction, rotating very close to the same speed, the transmission shaft “overdrives" the front gearcase input. The rollers are forced outward, disengaging the AWD. The vehicle is now back to rear wheel drive until the next loss of rear wheel traction.

Ring Gear

4x4 Engagement: When the A WD switch is activated, a 12 Vdc current charges the central coil, creating a magnetic field. This magnetic field attracts an armature plate keyed to a roller cage that contains 14 rollers and roller cam. The difference in rpm between the input shaft and front axles forces the rollers up the external cam. The rollers engage, or “wedge” themselves between the pinion gear and output hubs that link both front axles, resulting in true all wheel drive .

Magnetic Coil

Gearcase Removal

1. Stop engine, place machine in Park and set parking brake.

2. Loosen left front wheel nuts slightly.

3. Elevate the machine until the front wheels are off the ground and support machine under footrest/frame area.

CAUTION

Serious injury may result if machine tips or falls. Be

sure machine is secure before beginning this

service procedure. Wear eye protection when

removing and installing bearings and seals.

4. Remove left wheel nuts and wheel.

7.12

Page 13

FINAL DRIVE

5. Remove cotter pin, lower ball joint n ut and A-arm from ball joint.

6. Pull the hub and strut assembly out and pull the drive-shaft out of the hub.

8. Remove bolts securing the bottom of housing to the skid plate frame. Bolts and fluid drain plug are accessible through the skid plate.

9. Remove vent line.

10. Remove the front gearcase from left side of frame, pulling both the remaining CV shaft and propshaft from the gearcase. Replace the circlips on the CV shaft ends prior to reassembly.

7. Remove the roller pin from the front prop shaft. Use the

Roller Pin Removal Tool (PN 2872608).

Front Gearcase Removal

Remove 4 Bolts

Disassembly / Inspection

1. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet.

7.13

Page 14

FINAL DRIVE

2. Remove bolts retaining the outer cover plate assembly.

3. Remove the outer cover plate assembly. Thrust Bearing

4. Remove the armature plate and RH output hub assembly from the outer cover plate. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged

Output Hub Assembly

5. Remove the roll cage assembly, rollers, and ring gear.

Armature Plate

NOTE: Thrust bearing located between the two output hubs is pressed into assembly.

7.14

Page 15

FINAL DRIVE

6. Remove the LH output hub. Inspect the bearing and contact surfaces of the output hub for signs of wear or damage. Replace component if found to be worn or damaged.

7. Thoroughly clean all parts. Inspect the bearing surfaces of the output hub. Inspect the rol lers (A) for ni cks, scratch es and flat spots. Inspect the roll cage (B) for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces.

9. Inspect roll cage (B) sliding surface. This surface must be

clean and free of nicks, burrs or scratches. Inspect the H-

springs but do not remove them from the roll cage.

10. Inspect the armature plate for a consistent wear pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation.

NOTE: See “FRONT GEARCASE DIAGNOSIS” later in this chapter for more details.

H-Spring

8. Inspect the ring gear (C) for consistent wear patterns. The surfaces should be free of nicks or burrs.

7.15

Page 16

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11. Inspect the magnetic coil (A) in the outer cover plate assembly. Inspect the backlash pad (B) for excessive wear.

NOTE: See “FRONT GEARCASE DIAGNOSIS” later in this chapter for more det ail s on th e co il.

NOTE: The backlash for the centralize d hilliard is set at the factory. No adjustment is required, unless the front cover needs to be replaced, or the back lash pad screw is removed. See the “FRONT GEARCASE ASSEMBLY” procedure later in this chapter for details on backlash setting.

13. Remove the snap ring retaining the input shaft assembly.

14. Remove the input shaft assembly. Inspect the pinion gear (C) for chipped, broken, or missing teeth. Inspect the input shaft bearing (D) for signs of wear. Replace the input shaft cover O-ring prior to reassembly.

12. Remove the bolts retaining the input shaft cover and pinion gear assembly.

15. Inspect the input shaft bushing.

7.16

16. Thoroughly clean the gearcase components before beginning reassembly.

Page 17

FINAL DRIVE

Reassembly / Inspection

1. Replace all O-rings, seals, and worn components.

2. Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface.

3. Inspect bearings on output and pinion shafts. To replace, press new bearing on to shaft.

5. Install the LH output hub (A) into the gearcase housing. The output hub should spin freely.

6. Install the RH output hub (B) into the output cover. The output hub should spin freely.

4. Install input shaft, bearing, snap ring, and input cover with

new o-ring. Torque bolts to specification.

= T

Input Cover Bolt Torque

14 ft. lbs. (19 Nm)

7. Install the rollers and roll cage into the ring gear. Insert the rollers as the roll cage is installed.

7.17

Page 18

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8. Install the ring gear and roll cage assembly into the gearcase housing.

9. Install the armature plate on top of the roll cage / ring gear assembly. Be sure that the armature plate tabs are fully engaged into the roll cage assembly.

NOTE: Verify armature plate tabs a re p l a c ed in t o the slots on roll cage. (See Photo Below)

11. Torque the cover plate bolts to specification.

14 ft.lbs. (19 Nm)

= T

Output Cover Bolt Torque

14 ft. lbs. (19 Nm)

12. Lay the gearcase on the side with the output cover facing up.

10. Install the cover plate assembly with new o-ring onto the main gearcase.

NOTE: Verify the square O-ring is pl aced flat on the cover surface. If the O-ring is twisted fluid leakage may occur.

Setting Ring Gear Backlash

NOTE: Ring gear backlas h is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed.

1. The backlash screw has locking agent that holds it into place. Use a heat gun to lightly heat up the lo cking agent on the screw.

7.18

Page 19

FINAL DRIVE

2. Using a 3/32 hex wrench, turn the back-lash screw out 3-4 turns. Re-apply Loctite 262 threads.

3. Turn the screw in until it is lightly seated, th en turn the screw out 1/4 turn.

4. Set the gearcase upright. Rotate the input shaft at least 4 times. This ensures the ring gear completes one full rotation.

onto the bottom screw

NOTE: To test the gearcase coil resistance, use the coil harness. The gearcase coil should measure between 22.8 ohms and 25.2 ohms.

Front Gearcase Coil Resistance:

24 ±10%

2. Check the minimum battery voltage at the Grey & Brown/ White wires that feed the hub coil wires. There should be a minimum of 11.80-12.0 Volts operation.

present for proper

5. If a tight spot is felt during rotatio n, loosen the backlash screw another 1/8 turn. Perform the step 16 again. Repeat this procedure until the pinion shaft rotates smoothly 4 times (1 revolution of ring gear).

Front Gearcase Diagnosis

• Symptom: AWD Will Not Engage

1. Check the gearcase coil resistance. To test the gearcase coil resistance, use the coil harness (Grey & Brown/ White).

AWD Coil Applied Battery Voltage:

11.80-12.0 Vdc

3. Inspect the armature plate for a consistent wear pattern. There should be two distinct wear b ands (one band i nside the other). If only one band of wear is present (or if there is wear between the two bands, inspect the coil area as indicated in Step 4. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation.

Armature Plate

Check for Wear Bands

7.19

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FINAL DRIVE

4. Check to make sure the coil is seated in the U-shaped insert that is pressed into the gearcase cover. The top of the coil should be seated below the U-shaped insert. The U-shaped insert controls the pole gap. If the top of the coil is above the surface of the U-shaped insert it raises the armature plate, thereby increasing pole gap. If the pole gap increases the coil will not be strong enough to engage the AWD system. If this is the cause order a new Cover Plate Assembly.

Cutaway View of Gearcase Cover

Coil

U-Shaped Insert

Gearcase Installation

1. To install gearcase, reverse removal procedures. Use new roll pin in front prop shaft.

2. Torque mounting bolts in skid plate to 30 ft.lbs. (41 Nm).

30ft.lbs. (41 Nm)

= T

5. Inspect the rollers for nicks, scratches, and flat spots. Also inspect the roll cage for cracks and ensure the rollers are able to slide up and down and in and out freel y with in the roll cage sliding surfaces.

Rollers

Gearcase Mounting Bolt Torque:

30ft.lbs. (41 Nm)

New Roll Pin

3. Add the proper lubricant to the front gearcase. Check drain plug for proper torque. Refer to Chapter 2 for fluid fill and change information.

7.20

Page 21

FINAL DRIVE

FRONT GEARCASE - ACTIVE DESCENT CONTROL (DELUXE MODELS)

ADC Gearcase Exploded View (Deluxe Models)

Ref. # Description Qty Ref. # Description Qty

1 O-ring 2 17 Roll Cage Assembly 1 2

1/4

" Tubing

3 1/4-20 Screws 5 19 Spacer, Gear 1 4 Armature Plate 1 20 Pump Assembly 1 5 Bushing 1 21 Wire Connector 1 6 Vent 1 22 O-ring, Outer 2 7 Cap, Bleed Screw 2 23 O-ring, Inner 2 8 Spacer, Clutch Basket 1 24 Bleeder Valve 2

9 Cover Assembly 1 25 Cam Assembly 1 10 Cover Bracket 1 26 Armature Plate 1 11 Gear Case Sub-Assembly 1 27 Pinion Cover Assembly 1 12 Hose Clamp 2 28 Retaining Ring 1 13 Hub Sub-Assembly 2 29 Pinion Gear Assembly 1 14 Plastic Clip 2 30 Fill Plug 1 15 Reservoir 1 31 Drain Plug 1 16 Ring Gear 1 32 Piston Assembly 2

118

8-32 x 3/8" Screws

33 1/4-20 Screws 3

7.21

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FINAL DRIVE

Operation

Engaging Front Gearcase: Active Descent Control (ADC) is controlled by the ECU and will not enable until the following conditions are met:

• Vehicle speed is below 15 Mph (24Kph)

• Throttle Position Sensor (TPS) is at idle position

• The AWD switch is switched to ‘AWD’

Once the conditions are met for engagement, ADC remains engaged as long as the conditions are met.

With the AWD switch off, the vehicle drives only the rear wheels (2 wheel drive). When the AWD switch is ‘ON’ the magnetic coils are active, the AWD coil indexes the clutch mechanism so that both front axles will engage when there is a loss of rear wheel traction. In addition to the rear wheel engine braking, the ADC coil provides front wheel engine braking at speeds less than 15 Mph (24Kph) with the TPS at idle position.

ADC Engagement: When the AW D switch is activated, a 12 Vdc current is present at the input shaft coil (1). Operation is controlled by the ECU grounding and ungrounding the coil. The coil’s magnetic field attracts a s plined armature plate (2) on the pinion (input) shaft (4). The energized splined armature plate attracts the unsplined eccentric cam (3), which begins to t urn with the input shaft. The eccentric cam drives a hydraulic piston/pump assembly (5). The pressure created by the pump assembly forces hydraulic fluid through passages to the piston assemblies (6) located in each case half. Hydraulic pressure forces the piston assemblies inward to compress the splined clutch packs (7) forming a dynamic coupling to each front drive axle, resulting in true all-wheel EBS operation upon deceleration.

Disengagement: Current to the ADC coil is t urned off by the ECU anytime the following conditions are met:

• Throttle Position Sensor (TPS) moves off idle position

• The AWD switc h is switched to ‘OFF’

• Vehicle speed is above 15 Mph (24Kph)

Hydraulic pressure stops and the pistons release, disengaging the ADC function. The vehicle returns to rear wheel drive until the next deceleration.

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FINAL DRIVE

ADC Coil Testing

Refer to the following tests in Chapter 10: See “ACTIVE DESCENT CONTROL (ADC) COIL” on

page 10.15.

See “ALL WHEEL DRIVE (AWD) COIL” on page 10.15.

ADC Differential Hydraulic Circuit Bleeding

1. Make sure vehicle is parked on flat ground and allowed to sit at least 30 minutes prior to bleeding hydrauli c circuit.

2. Thoroughly clean area around and on remote reservoir and hydraulic bleeders.

3. Remove reservoir cap and diaphragm assembly.

4. Make sure hydraulic oil inside reservoir is free of debris. If any debris is found, use clean rag or suction device to remove from the reservoir.

NOTE: Debris in reservoir may block porting and produce inadequate bleeding of the system. Decreased performance may be encountered with inadequate bleed of the hydraulic circuit.

5. Begin the bleeding process by filling reservoir to ‘MAX’ line with clean Polaris ADC oil . (AW ISO 10 hydrauli c fluid equivalent).

6. Locate bleeder valves found on either side of differential and remove the protective caps.

7. Turn bleeder valves counter-clockwise to lo osen. Loosen bleeder screw slowly, allowing oil and any trapped air to flow out of fitting.

IMPORTANT: Do not allow hydraulic fluid in reservoir to drain below minimum fill line. Close bleeder va lve

before oil level falls below minimum fill line. Refilling empty reservoir will resu lt in air pockets becoming trapped.

Disassembly / Inspection

NOTE: See “Gearcase Removal” on page 7.12.

1. Drain and properly dispose of used oil. Remove any metal particles from the drain plug magnet.

2. Remove the piston pump assembly from the gearcase.

NOTE: Piston pump assembly is a non-serviceable item and should not be diassembled. Replace as an assembly if found to be damaged or non-working.

3. Remove bolts (arrows) retaining the outer cover plate assembly.

NOTE: If empty reservoir is encountered, filling of fluid is still possible. Verify air is not trapped before proceeding with step 7.

8. Continue steps 6-8 on both sides in sequ ence until no air bubbles are seen when bleeding occurs.

9. Re-torque both bleeder valves to specification and reinstall cover caps.

= T

Bleeder Valve Torque:

80 in. lbs. (9 Nm)

10. Fill reservoir with to a level midway between ‘M AX’ and ‘MIN’ fill lines. Verify no debris is found in reservoir oil.

11. Replace reservoir cap securely and wipe clean any residue.

7.23

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FINAL DRIVE

4. Remove the outer cover plate assembly. Remove and inspect the cover o-ring (1). Inspect thrust bearing (2 ) for wear. Replace items as required.

NOTE: Thrust bearing (2) located between the two output assemblies is pressed into the clutch pack and is not removable.

5. Remove the output clutch assemblies. Inspect the bearings, contact surfaces and splines of the output clutch for signs of wear or damage. Visually inspect the clutch plate area. If plates are steel-on-steel, or if the friction material is worn, the assembly should be replaced.

6. Remove the armature plate. Inspect the armature plate for wear, distortion or other damage. Replace component as required.

7. Remove the spacer. Inspect for signs of wear or damage. Replace component as required.

NOTE: locating pins (arrow) are for spacer installation. Note for reassembly.

NOTE: Excessive debris in the oil and/or noise coming from the front drive on deceleration are key indicators of clutch pack failure. Replace clutch as an assembly if found to be worn or damaged.

NOTE: Locating pins / holes (circle) aid installation. Note for reassembly.

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FINAL DRIVE

8. Remove the ring gear (1) and spacer (2).

9. Remove and inspect the bearing surfaces of the output hub.

10. Thoroughly clean all parts.

11. Inspect the rollers (1) for nicks, scratches and flat spots. Inspect the roll cage (2) for damage or cracks. The rollers must slide up and down freely within the roller cage surfaces. Inspect the ring gear (3) for consistent wear patterns. Surfaces should be free of nicks or burrs.

12. Inspect roll cage sliding surface (2). This surface must be clean and free of nicks, burrs or scratches. Remove and inspect the H-springs (4). Replace any components as required.

13. Inspect the armature plate for a consistent wear pattern. Uneven wear of the armature plate indicates a warped plate, which may cause intermittent operation.

NOTE: See “Front Gearcase Diagnosis” on page 7.19.

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Page 26

FINAL DRIVE

14. Inspect the magnetic coil (1) in the outer cover plate assembly. Inspect the backlash pad (2) for excessive wear.

NOTE: See “FRONT GEARCASE DIAGNOSIS” in this chapter.

NOTE: Ring gear backlash (2) is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed. See the “FRONT GEARCASE ASSEMBLY” in this chapter for details on backlash setting.

16. Inspect the magnetic coil (1) and bushing in the input cover plate assembly. Replace the input cover seal.

17. Remove the splined armature plate (1).

15. Remove the bolts retaining the input shaft cover and pinion gear assembly.

18. Remove the eccentric cam assembly. Inspect the cam (1) and bushing (2) for wear or damage. Replace component as required.

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FINAL DRIVE

19. Remove the snap ring retaining the input shaft assembly.

20. Remove the input shaft assembly. Inspect the pinion gear (1) for chipped, broken, or missing teeth. Inspect the input shaft bearing (2) for signs of wear. Replace the input shaft cover O-ring (3) prior to reassembly.

ADC Gearcase Piston Replacement Procedure

CAUTION

This repair procedure involves the

use of compressed air. Safety glasses

or a face shield are required.

1. Place ADC Piston Tool PA-48542 on t op of the piston. Using moderate hand pressure, hold the tool on top o f the piston while using compressed air at the gearcase passage (circled) to force piston up and out of the case. (See photo)

AIR

ADC Piston Tool

PA-48542

21. Inspect the input shaft bushing. Replace case if worn.

2. Repeat procedure for the other piston. (See photo)

AIR

PA-48542

3. Remove and discard the inner and outer o-rings from the piston assembly.

NOTE: Never re-use o-rings. Always replace with new.

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FINAL DRIVE

4. Coat new piston and o-rings with a moderate amoun t of white lithium grease or assembly lube. Coat the edges of the piston cavities. Install the inner and outer piston o-rings.

Outer

Inner

5. Place the piston in the piston cavity, aligning the pins with the pin bosses. Using the casting and piston marks as a guide as shown will aid pin alignment.

6. Place ADC Piston Tool PA-48542 on top of the piston and verify alignment of the sight hole (circled) and piston mark with the casting marks. Support the case and press the piston down evenly. The piston is fully seated and located in the pin bosses when the piston surface is just below the cavity edge.

Tool PA-48542

7. Repeat procedure for the other gearcase half.

NOTE: Verify that the o-rings are seated properly and that no o-ring shavings exist outside of the piston area, which is an indication of damage during installation.

7.28

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FINAL DRIVE

Assembly

1. Thoroughly clean the gearcase components before beginning reassembly.

2. Install a new seal in the main gearcase halve.

3. Install the input shaft assembly. In stall the pinion gear/ bearing assembly (1). Install a new seal and o-ring the input shaft cover (2) prior to reassembly.

4. Install the snap ring retaining the input shaft assembly.

5. Install the eccentric cam assembly (1).

6. Install the splined armature plate (1).

7. Install the input shaft cover assembly, bolts and bracket. Torque to specification.

= T

Input Cover Bolt Torque:

7-11 ft. lbs. (9.4-14.9 Nm)

7.29

Page 30

FINAL DRIVE

8. Install a new seal (1) in the outer cover plate assembly. Install a new o-ring on the backlash pad (2) stem .

NOTE: Ring gear backlash (2) is set at the factory. No adjustment is required, unless the front cover is replaced or the back lash pad screw is removed.

9. Install the roll cage and rollers into the ring gear. Insert the rollers as the roll cage is installed.

10. Install the clutch pack (1), spacer (2) and ring gear (3).

NOTE: Align locating pins / holes for in stallation.

11. Install the spacer.

NOTE: Align locating pins / holes for installation (arrow).

7.30

12. Install the armature plate. Verify the armature plate tabs align with tab recesses in the roll cage.

Page 31

FINAL DRIVE

13. Install new cover o-ring (1) on the cover plate assembly and a new passage o-ring (2) on the gear case.

14. Install the remaining output clutch assembly.

NOTE: Align locating pins / holes for installati on.

15. Place cover assembly on Install bolts (arrows) retaining the outer cover plate assembly and torque to specification.

= T

Input Cover Bolt Torque:

7-11 ft. lbs. (9.4-14.9 Nm)

16. Install a new passage o-ring (dotted circle) on the gearcase and install the piston pump assembly. Torque the screws to specification.

= T

Pump Assembly Screw Torque:

17-23 in. lbs. (1.9-2.5 Nm)

NOTE: See “Gearcase Installation” on page 7.20.

7.31

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FINAL DRIVE

REAR HUB

Removal

1. Place the ATV in Park and lock the parking brake. Remove rear hub cap.

8. Remove hub nut, domed washer and flat washer.

9. Remove hub.

2. Remove cotter pin (A).

3. Loosen the hub retaining nut (B).

4. Loosen the wheel nuts (C).

5. Safely support the rear of the ATV.

6. Remove wheel nuts and wheel.

7. Remove the rear brake caliper and safely suspend the caliper from the frame with a piece of wire.

10. Remove upper control arm bolt as shown.

7.32

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FINAL DRIVE

11. Remove both lower control arm bolts.

12. Remove bearing carrier.

Disassembly

1. Remove outer snap ring.

2. From the back side, tap on the outer bearing race with a drift punch in the reliefs as shown or press out using a hydraulic press.

NOTE: Drive bearing out evenly by tapping on outer race only. Once bearing is at bottom of casting, support casting on outer edges so bearing can be removed.

3. Inspect bearing.

4. Inspect bearing housing for wear or damage. Replace housing if damaged.

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FINAL DRIVE

Assembly

1. Support bottom of bearing carrier housing.

2. Start bearing in housing.

3. Press bearing into place until outer race bottoms on housing.

CAUTION

Use an arbor press only on the outer race

to avoid bearing damage.

4. Install snap ring into groove.

Installation

1. Insert bearing carrier on drive shaft.

2. Align bottom of carrier housing and lower control arm. Grease and slide lower control arm bushings into place, securing corner housing.

3. Install and torque both lower control arm bolts.

7.34

= T

Upper Control Arm Bolt Torque:

35 ft. lbs. (48 Nm)

Page 35

= T

Lower Control Arm Bolt Torque:

50 ft. lbs. (68 Nm)

4. Lift bearing carrier until top aligns with upper control arm. Install and torque upper control arm bolt and torque to specification.

5. Pull drive shaft outward and install hub onto driveshaft splines.

6. Install cone washers with domed side facing outward.

7. Install retainer nut, wheel and wheel nuts.

8. Remove jackstand and torque axle nut and wheel nuts to specification.

FINAL DRIVE

REAR DRIVE (CV) SHAFT

Removal

1. Remove rear hub, see “REAR HUB REMOVAL”.

2. Remove upper carrier bolt. Tip hub outward and rem ove shaft from carrier.

= T

Wheel Nut Torque:

See “Torque Table” on page 7.2.

= T

Hub Nut Torque:

80 ft. lbs. (109 Nm)

9. Install a new cotter pin. Tighten nut slightly to align holes if required.

3. Pull sharply outward to remove shaft from transmission. Install a new lock ring upon assembly.

Pull outward sharply to remove from transmission

Lock Ring

7.35

Page 36

FINAL DRIVE

Service

1. Remove clamps from rubber boot(s) using the CV Boot

Clamp Pliers (PN 8700226) (A).

2. Photo below is shown without shaft for clarity. Wipe grease away from recess in CV joint inner hub to locate snap ring

3. Open the snap ring using a snap ring pliers or small needle nose pliers. Tap CV housing off shaft with a soft faced hammer while holding snap ring open.

Spread ends of snap ring to remove joint from shaft

Tap CV housing off shaft

4. Place a new snap ring in the groove of the CV joint inner hub, with tabs facing the shaft as shown.

Snap Ring Located in recessed area

Snap Ring

Tabs face shaft

7.36

Page 37

FINAL DRIVE

5. Refit CV joint on interconnecting shaft by tapping with a plastic hammer on the joint housing. Take care not to damage threads on the outboard CV joint. The joint is fully assembled when the snap ring is located in the groove on the interconnecting shaft.

Tap joint onto shaft

6. Install and tighten large boot clamp with boot clamp pliers.

7. Remove excess grease from the CV joint's external surfaces and position joint boot over housing, making sure boot is seated in groove. Position clamp over boot end and make sure clamp tabs are located in slots. NOTE: Before tightening boot clamp on inboard joint, make sure any air pressure which may have built up in joint boot has been released. The air should be released after the plunging joint has been centered properly. Tighten boot clamp using boot clamp pliers.

Open snap ring and pull CV joint away from shaft

CV Boot Replacement

1. Remove CV joint from end of shaft.

2. Remove boot from shaft.

NOTE: When replacing a damaged boot, check the grease for contamination by rubbing it between two fingers. A gritty feeling indicates contamination. If the grease is not contaminated, the boot can be replaced without cleaning the CV joint. Use the recommended amount of grease for boot replacement only (see below). Proceed to Boot Installation.

3. Thoroughly clean and dry the CV joint and inspect ball tracks and cages for wear, cracks or other damage.

NOTE: Shiny areas in ball tracks and on the cage spheres are normal. Do not replace CV joints because parts have polished surfaces. Replace CV joint only if components are cracked, broken, worn or otherwise unserviceable.

4. Add the recommended amount of grease for CV joint cleaning to the joint as shown below. Be sure grease penetrates all parts of the joint.

6. Add grease through large end of boot.

7. Install a new boot onto the axle shaft and fi ll th e CV joint and boot with the correct type and amount of grease.

7.37

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FINAL DRIVE

8. While pulling out on the CV shaft, fully extend the CV joint and slide a straight O-ring pick or a small slotted screw driver between the small end of the boot and the sha ft. This will allow the air pressure to equalize in the CV boot in the position that the joint will spend most of its life. Before you remove your instrument, be sure the small end of t he b oot is in its correct location on the axle.

9. Install the small clamp on the boot.

10. Be sure to use only the Constant Velocity Joint grease supplied with boot service kit. IF CV JOINT WAS CLEANED, add the recommended amount of grease to the joint in addition to the grease pack supplied with boot kit.

NOTE: CV Joint Grease Capacity:

INSTALLATION

1. Slide shaft assembly into bearing carrier hub.

2. Apply anti-seize compound to splines of shaft.

3. Install a new lock ring and install the shaft.

4. Lift bearing carrier into place and install bolt to upper control arm. Torque bolt to specification.

Joint Capacity 50 grams

Boot Capacity 30 Grams

Outboard - 80g Total

CV Joint Grease:

30g PN 1350046 50g PN 1350047

Outboard Joint total) if joint is cleaned.

Inboard Joint total) if joint is cleaned.

- 30g if boot is replaced only. Another 50g (80

- 50g if boot is replaced only. Another 50g (100

Joint Capacity - 50 grams

Boot Capacity - 50 grams

Inboard - 100g Total

= T

Upper Hub Carrier Bolt Torque:

35 ft. lbs. (48 Nm)

5. Install hub, flat washer, domed washer (domed side out) and nut. Torque center hub nut to specification. Install new cotter pin and hub cap.

= T

Hub Nut Torque:

80 ft. lbs. (109 Nm)

7.38

Page 39

FINAL DRIVE

6. Install rear wheel and torque wheel nuts to specification.

80 ft.lbs. (109 Nm)

Refer to Page 7.2 for Wheel Nut Torque.

7. Grease all fittings thoroughly with Premium U-Joint

Lubricant (PN 2871551).

Drive Shaft and CV Joint Handling Tips

Care should be exercised during driveshaft removal or when servicing CV joints. Driveshaft components are precision parts.

Cleanliness and following these instructions is very important to ensure proper shaft function and a normal service life.

• The complete driveshaft and joint should be handled by getting hold of the interconnecting shaft to avoid disassembly or potential damage to the driveshaft

joints.

REAR GEARCASE

Removal

1. Place ATV on a level surface and place transmission in ‘PARK’.

2. Loosen both rear wheel nuts.

3. Loosen both rear center hub nuts.

4. Lift and safely support rear of ATV so that the rear wheels are off the ground.

5. Remove the roll pin from the rear transmission yoke and pull vent line off the gearcase.

6. Remove both rear wheels and center hub nuts.

NOTE: Hub removal is not required to remove CV shafts.

7. Remove both upper hub carrier bolts. Tilt hubs outward and remove both CV shafts.

8. Remove the upper and lower bolts from the gearcase mounts.

9. Pull gearcase out the rear of the vehicle. Some p rying and tapping with a soft-face hammer may be required. Use care not to damage other components.

Disassembly and Inspection

1. Drain and properly dispose of used oil.

2. Remove the gearcase housing cover bolts and the gearcase housing cover.

• Over-angling of joints beyond their capacity could result in boot or joint damage.

• Make sure surface-ground areas and splines of shaft are protected during handling to avoid damage.

• Do not allow boots to come into contact with sharp edges or hot engine and exhaust components.

• The driveshaft is not to be used as a lever arm to position other suspension components.

• Never use a hammer or sharp tools to remove or to install boot clamps.

• Be sure joints are thoroughly clean and that the proper amount and type of grease is used to refill when joint boots are replaced and when joints are cleaned. Refer to text for grease capacity of CV joints and CV joint boots.

7.39

Page 40

FINAL DRIVE

3. Remove the shim, thrust button, and thrust button shim from the gearcase.

Thrust Button

Shims

5. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed.

6. Remove the input shaft cover and the pinion sh aft from the gearcase housing. See next page.

7. Inspect the ring gear for abnormal wear, broken, or chipped teeth. Spin the bearing to check the ball bearings for smoothness. Replace the bearing if needed.

4. Remove rear bevel gear from the gearcase housing. cover.

7.40

Page 41

Reassembly

1. Inspect the pinion shaft bushing for wear.

2. Replace all O-rings, seals, and worn components.

FINAL DRIVE

= T

Input Cover Bolt Torque:

25 ft.lbs. (34 Nm)

4. Install the original shim(s), thrust button, and thrust button shims into the gearcase cover.

3. Install the pinion shaft into the gearcase housing. Install the pinion shaft cover and torque the cover bolts to specification.

5. Apply Crankcase Sealant (PN 2871557) to surface of case

and install cover bolts. Install the gearcase cover onto the gearcase housing. Torque the cover bolts in a criss-cross pattern to specification.

= T

Cover Bolt Torque:

25 ft.lbs. (34 Nm)

7.41

Page 42

FINAL DRIVE

6. Install the drain plug and fill plug. Replace the drain plug washers to ensure proper sealing after filling.

Fill Plug

Drain Plug

= T

Drain / Fill Plug Torque:

14-18 ft.lbs. (19-24 Nm)

Installation

1. To install the rear gearcase, reverse the removal procedures.

2. Pre-install the propshaft onto the transmission and insert the roll pin. While installing the gearcase, align the propshaft and gearcase input shaft for easier propshaft installation. Use of anti-seize compound on the shaft splines is recommended.

3. Torque the gearcase mounting bolts to specification.

4. Re-install CV shafts, hubs, carrier bolts, et c. and torque to specifications.

= T

Lower Control Arm Bolt Torque:

50 ft. lbs. (68 Nm)

= T

Upper Control Arm Bolt Torque:

35 ft. lbs. (48 Nm)

= T

Hub Nut Torque:

80 ft. lbs. (109 Nm)

= T

Wheel Nut Torque:

See “Torque Table” on page 7.2.

5. Re-install gearcase vent line.

6. Refill the rear gearcase with Polaris Premium Gearcase Lubricant (PN 2871653). Refer to the “REAR GEARCASE LUBRICATION” procedure in Chapter 2.

7.42

= T

Gearcase Mounting Bolts

30 ft.lbs. (41 Nm)

Page 43

Rear Gearcase Exploded View

FINAL DRIVE

7.43

Page 44

FINAL DRIVE

NOTES

7.44