Rear Axles - Polaris 1999 Sportsman 400 Service Manual

REAR SUSPEI'iSIO N
12. Install the rear axle bea ring carr ier as descri bed
in this chapter,
REAR AXL ES
Refer to Figure 9.
Removal
1. Place the vehicle on a level surface and block the
front whee ls so the vehicle ca nno t roll in any d irec-
tion .
2. Remove the rear hub and the rear axle bearing
ca rrier as describ ed in this chapter.
3. Prior to removing the rear axfci s). mark the m
with a R (right side) (Figure 31l) or L (lett side) so
they will be rei nstalled on the same side.
4A. On 1996- 1998 models, perform the foll owing:
NO TE
The internal threaded spacer
lvil/ If SIt -
all y remain with the right side rear
ax le. It may remain attached to either
rellr
axle during
this
procedure. Be
sure to remove the spacer when re-
371
movi ng both real' axl es and mak e sure
it
is correctly secured to one ofthe ax-
les du ring installa tion.
NOTE
The CJl16 in. bo lts are se cured to the
internal threaded spacer with a
ttneadlock ing compound and may he
difficult
10
loo sen.
a. Usc a 9/ 16 in. open end wrench and loosen the
attachment
bolt
sec uring the inner unive rsal
j oint to the interna l threaded spacer located
within the transmis sion output gear,
h. Hold ont o the rear axle, slowly pu ll the rear
ax le out of the transmission while loosening
the bolt.
c. Remov e the rear axle from the transmission
and
frame.
43. On 1999-on model s, perfo rm the followin g :
a. Hold the rear ax le straight ou t from the trans-
missio n (F igur e 31).
b. Pull sharply outward on the rear axle to d is-
lodge the inner CV joi nt locking ring from the
transm ission output ge ar.
c. Remo ve the rear axle from the transmission
and frame.
5. Repeat for the other rear axle.
6. Inspec l the rear axle as descr ibed in this chapter.
Inspection
I. Thoroughly clea n the exterior ofthe rea r ax le(s)
II
in solvent.
NOTE
Rubber
boot replacement requires
partial disasse mbly (!( the rear axle.
The
rear axle components
must be
cleaned, repacked lind align ed during
assem bly, the refore ref er this service
to a Polaris dealership,
CAU 710N
0/1 a/l mo de ls, it is suggested that the
rubber boo sts) be replaced by a Po-
laris dealership, Ifthe rear axle is dis-
ass em bled
f or
boot
replacement
on
1~9 6- 199 8 models, it must be assem-
bled co rrectly,
During assembly; the
inboard and outboard U-joim yokes
must be aligned as shown ill Figu re
3210 avoid excessive
vibration,