Gearcase Bearing And Seal Replacement - Polaris 2009 Sportsman XP 850 Service Manual

Gearcase Bearing and Seal Replacement

1. If the gearcase is completely assembled, perform the
"Gearcase Disassembly and Inspection" procedure.
2. Remove the nut and locking washer(s) from the pinion shaft
(nut was loosened during "Gearcase Removal").
3. Using a universal bolt-grip puller kit, remove the coupler
from the pinion shaft.
4. Remove the seal above the pinion shaft using a seal puller
or other suitable method (see Figure 8-27).
°
180 Bolt-Grip Puller
Figure 8-27
5. Remove the retaining ring and lift the pinion shaft and
bearing from the main gearcase (see Figure 8-27).
6. Support the pinion shaft and press the bearing off the shaft
(see Figure 8-27).
7. Thoroughly clean the pinion shaft.
8. Support the pinion shaft and carefully press the new bearing
on the shaft and install a NEW O-ring (see Figure 8-27).
WARNING
Wear appropriate safety equipment while
installing bearings to reduce the risk of injury.
9. Remove the seals from each case half using a seal puller or
other suitable method (see Figure 8-28).
10. Support the gearcase cover and press the bearing out.
Repeat this procedure on the main gearcase half (see Figure
8-28).
11. Thoroughly clean the gearcase halves.
12. Support the gearcase cover and carefully press in the new
bearing. Repeat this procedure on the main gearcase half
(see Figure 8-28).
WARNING
Wear appropriate safety equipment while
installing bearings to reduce the risk of injury.
FINAL DRIVE
8
Figure 8-28
8.41