Gearcase Installation - Polaris 2009 Sportsman XP 850 Service Manual

Gearcase Installation

1. Install the coupler onto the pinion shaft splines.
2. Install the locking washer(s) and retaining nut.
3. Torque the retaining nut to specification.
Coupler Retaining Nut Torque:
90-110 ft. lbs. (122-149 Nm)
4. Install the rear gearcase by reversing the "Gearcase
Removal" procedure at the beginning of this section. Refer
to the following steps for torque specifications.
5. Install the gearcase through-bolt mounting fasteners and
torque to specification.
NOTE: Use the longer bolts (150 mm) in the top and
the shorter bolts (125 mm) in the bottom.
Gearcase Mounting Fasteners:
40 ft. lbs. (54 Nm)
6. Install the right rear drive shaft and the upper A-arm onto
the bearing carrier. Torque through-bolt fastener to
specification.
Rear Upper A-arm to Bearing Carrier:
40 ft. lbs. (54 Nm)
7. Install the cone washers (dome facing retaining nut) and
right rear hub retaining nut. Torque to specification and
install a new cotter pin.
Rear Hub Retaining Nut:
80 ft. lbs. (108 Nm)
8. Install the left rear drive shaft and suspension assembly.
Torque the upper and lower A-arms to specification.
Rear Upper & Lower A-arms to Frame:
45 ft. lbs. (61 Nm)
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9. Install the left rear brake caliper and brake line retainer.
Torque brake caliper mounting bolts to specification.
Brake Caliper Mounting Bolts:
37 ft. lbs. (50 Nm)
10. Install the rear upper shock through-bolts. Torque bolts to
specification.
Rear Upper Shock Bolts:
37 ft. lbs. (50 Nm)
11. Install the rear stabilizer bar onto the linkage rods. Torque
the linkage retaining nuts to specification.
Stabilizer Bar Linkage Retaining Nuts:
17 ft. lbs. (23 Nm)
12. Install the rear propshaft and torque bolts to specification.
Rear Propshaft Bolts:
18 ft. lbs. (24 Nm)
13. Reassemble the PVT system (see Chapter 7 "PVT
SYSTEM SERVICE - Assembly").
14. Install the rear wheels and torque wheel nuts to
specification (see Page 8.2).
15. Add Polaris ATV Angle Drive Fluid to rear gearcase (see
Chapter 2). Torque drain and fill plugs to specification.
Rear Gearcase Capacity:
7.1 fl. oz. (210 ml)
or to bottom of fill plug hole threads
See Chapter 2 "Maintenance"
Drain / Fill Plug:
10-14 ft. lbs. (14-19 Nm)
FINAL DRIVE
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