Rear Gearcase Removal - Polaris SPORTSMAN 600 Service Manual

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 PROPSHAFT
REMOVAL/INSTALL
Rear Gearcase
Propshaft
1. Loosen or remove the bolts the bolts that secure
the rear gearcase to the frame. Slide the rear
gearcase back enough to slide the rear propshaft
from the transmission shaft. Remove the rear
drive shaft.
2. To install the rear propshaft:
Slide transmission end of propshaft
G
onto the transmission output shaft
Slide the rear gearcase back into
G
place and align propshaft to rear
gearcase input shaft
Joint Capacity
50 Grams
INBOARD
100g Total
Boot Capacity
50 Grams
Transmission
Tighten the rear gearcase as shown
G
in illustration 1.
D
30 ft. lbs
. (41 Nm)
B
(5 bolts)
C
30 ft. lbs. (41
30 ft. lbs. (41 Nm)
Nm) (4 bolts)
(5 bolts)

REAR GEARCASE REMOVAL

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.
FINAL DRIVE
30 ft. lbs. (41 Nm)
(2 bolts)
C
B
C
Remove Propshaft
A
Ill.1
7.33