Rear Gearcase Removal; Rear Gearcase Installation - Polaris SPORTSMAN 600 2003 Service Manual

FINAL DRIVE FINAL DRIVE
Joint Capacity
50 Grams
OUTBOARD
80g Total
Boot Capacity
30 Grams
NOTE: CV Joint Grease Capacity:
CV Joint Grease - 30g (PN 1350046)
50g (PN 1350047)
Outboard joint - 30g if boot is replaced only. Another
50g (80 total) if joint is cleaned.
Inboard joint - 50g if boot is replaced only. Another
50g (100total) if joint is cleaned.

REAR GEARCASE REMOVAL

D
30 ft. lbs
. (41 Nm)
B
(5 bolts)
C
30 ft. lbs. (41
30 ft. lbs. (41 Nm)
Nm) (4 bolts)
7.24
Joint Capacity
50 Grams
INBOARD
100g Total
Boot Capacity
50 Grams
30 ft. lbs. (41 Nm)
(2 bolts)
C
B
C
A
Ill.1
CAUTION: Serious injury may result if the machine
tips or falls. Be sure the machine is secure before
beginning this service procedure.
1. Place the ATV in park and set the parking brake.
2. Jack up the rear of the ATV and safely support the
ATV with jackstands.
3. Remove the two rear tires.
4. Remove the rear prop shaft from the rear
gearcase.
5. Remove the rear drive shafts. Refer to the "Rear
Drive Shaft Removal" section.
6. Remove the upper shock mounting bolt.
7. Remove the four mounting bolts and washers (A)
on the underside of the rear gearcase.
8. Remove the two mounting bolts and washers (B)
from the front of the rear gearcase.
9. Remove the five bolts, nuts, and washers, (C) and
(D), that hold the gearcase to the frame.
NOTE: To remove the bottom bolts (C) from the rear
gearcase the lower control may have to be removed.
10. Pull the gearcase from the frame.
REAR GEARCASE
INSTALLATION
1. To install the rear gearcase, reverse the removal
procedures.
Fill Plug
2. Torque the installation bolts and nuts to the
torques specified in Ill. 1.
3. Refill the rear gearcase with 5 oz. (150 ml) of
Polaris Premium Gearcase Lubricant (PN
2871653). Torque the fill plug to 14 ft. lbs. (19
Nm).