Gearcase Installation - Polaris MS4000 Service And Owner's Manual

Middle Gearcase Specifications:
Capacity: 6.75 oz. (200 ml)
Specified Lubricant: ATV Angle Drive
Fluid (PN 2871653)
Fill Plug Torque: 14 ft. lbs. (19 Nm)

Gearcase Installation

1. Place the middle gearcase in the frame assembly.
A
D
2. Attach the mid and rear prop shafts to the mid gearcase, but
do not install the new roll pins yet.
3. Install the four middle drive gearcase bolts. Torque the
bolts to 30 ft. lbs. (41 Nm) in a cross pattern.
4. Install a new roll pins into the mid and rear prop shafts and
middle gearcase input and rear output shafts.
5. Install the mid drive shafts (D) onto the mid gearcase (B).
6. Install the vent tube (A) and clamp.
7. Lift bearing carrier into place and install bolt to upper
control arm. Torque bolt to 35 ft. lbs. (47 Nm). Refer to the
"MID DRIVE SHAFT INSTALLATION" section for
more details.
8. Install hub, flat washer, domed washer (domed side out)
and nut. Torque center nut to 110 ft. lbs. (149 Nm). Install
new cotter pin and hub cap.
9. Install rear wheel and torque wheel nuts to specification.
10. Install the parking brake caliper (C), refer to Chapter 9,
"Parking Brake Caliper Service - Caliper Installation"
B
C
D
FINAL DRIVE
7
7.35