Gearcase Assembly - Polaris 2009 Sportsman XP 850 Service Manual

FINAL DRIVE
13. Install the seals into the case halves using a standard seal
installer or other suitable method. Seal depth should be
approximately .110 in. (2.79 mm) from the main surface.
14. Install the pinion shaft into the main gearcase and secure
with a NEW retaining ring.
15. Install the seal into the main gearcase half using a standard
seal installer or other suitable method. Press seal into the
gearcase until it bottoms out in the housing.
8.42

Gearcase Assembly

1. Grease all seals with Polaris All Season Grease (PN
2871322) upon assembly to prevent from damaging seals.
2. Install the ring gear into the main gearcase.
3. Install the shim previously removed onto the ring gear.
4. Thoroughly clean the gearcase mating surfaces and be sure
the alignment pins are in place.
5. Apply Crankcase Sealant (PN 2871557) to mating surfaces.
6. Install the gearcase cover onto the main gearcase half.
7. Install the cover screws and torque to specification.
Cover Screw Torque:
15-20 ft. lbs. (20-27 Nm)
8. Proceed to "Gearcase Installation" before installing the
coupler, locking washer(s), and retaining nut. Doing so will
allow you to properly torque the coupler retaining nut.
Shim
= T