Gearcase Removal; Gearcase Disassembly / Inspection - Polaris 2009 Ranger RZR 800 EFI Manual

Gearcase Removal

1. Stop engine and place gear selector in Park.
2. Refer to "FRONT DRIVE SHAFT - Drive Shaft Removal"
and remove both front drive shafts from the front gearcase.
3. Remove the propshaft (see "PROPSHAFT SERVICE").
4. Disconnect the wire harness above the front gearcase and
remove the harness from the retaining dart.
5. Remove the vent line from the front gearcase.
6. Remove the (4) bolts securing the front gearcase to frame.
Disconnect
Harness
Remove 4 Bolts
7.
AWD Harness

Gearcase Disassembly / Inspection

1.
2.
Remove
Vent Line
3.
4.
Remove the gearcase from the front LH wheel well area and
slide it between the upper and lower A-arm.
Drain and properly dispose of gearcase fluid. Remove any
metal particles from the drain plug magnet.
Remove the (6) cover screws and remove the cover plate.
Check the gearcase coil resistance (see "AWD Diagnosis").
The resistance value should meet the specification.
Remove and inspect the armature plate and thrust plate.
Refer to "AWD Diagnosis" for detailed inspection process.
Armature
Plate
FINAL DRIVE
7
Thrust
Plate
7.17