Polaris SPORTSMAN 600 Service Manual page 185

EARLY 2004 - - FRONT
GEARCASE
REASSEMBLY/INSPECTION
1. Replace all O--rings,
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.
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 side to side.
4. Install pinion shaft, bearing, and input cover with
new o-ring and torque bolts to 14 ft. lbs (19 Nm).
Cover Bolts Torque
14 ft. lbs. (19 Nm)
5. Install the output hub into the gearcase housing.
The output hub should spin freely.
seals, and worn
6. Install the ring gear into the gearcase housing.
7. Slide the roll cage into the ring gear. Insert the
rollers as the roll cage is installed.
FINAL DRIVE
7.13