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FINAL DRIVE
Front Gearcase
Front Gearcase Disassembly
7.
Using an 1/8" drill bit, remove rivet securing side
cover to front gearcase.
8.
Loosen both Allen screws securing side cover to
front gearcase (1996 models only).
NOTE: There are no Allen screws on output cover on
1997 front gearcase.
9.
Install spanner tool on side cover.
Use 2 1/8"
wrench on spanner tool to remove side cover.
Turn cover counterclockwise as viewed from the
right side (standard threads).
1 O. Remove cover, thrust washer, steel spacer, ring
gear assembly and shaft.
Clean all parts and
inspect spacers for wear. Inspect ring gear for
chipped, broken, or missing teeth.
NOTE: Due to extremely close tolerances and mini-
mal 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-
ways between inner and outer race.
10/96
7.46
Polaris Industries Inc.
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Troubleshooting
