Gearcase Disassembly And Inspection - Polaris 2009 Sportsman XP 850 Service Manual

FINAL DRIVE

Gearcase Disassembly and Inspection

IMPORTANT: Pinion
information is NOT provided. The components are
matched at the factory which requires special OEM
tooling in order to properly assemble and shim the
gears.
In the event damage to the gears or housing requires
replacement, the entire assembly must be replaced.
1. Drain and properly dispose of used gearcase lubricant.
2. Remove the (8) screws from the rear gearcase cover.
3. Lift the gearcase cover off the main gearcase half and note
the shim between the cover and the ring gear.
4. Remove the ring gear from the main gearcase half.
Ring Gear
8.40
and ring gear shimming
Shim
5. Inspect the ring gear teeth for chipped, worn, or broken
teeth.
6. Inspect the pinion shaft by rotating the assembly in the
gearcase housing while checking for any looseness or
roughness. Inspect the pinion gear teeth for chipped, worn,
or broken teeth.
Inspect the
gear teeth
NOTE: In the event damage to the gears or housing
requires replacement, the entire assembly must be
replaced.
7. Inspect the gearcase bearings and seals.
"Gearcase Bearing and Seal Replacement" if components
require service.
Proceed to