Front Gearcase Removal - Polaris SPORTSMAN 600 2003 Service Manual

FINAL DRIVE FINAL DRIVE
2. Using a suitable arbor or vise, fully seat bearing
cap in one side.
movement of bearing cross as bearing caps are
assembled.
3. Install snap ring to contain bearing cap just
installed. Repeat procedure for other side.
4. Install outer yoke, aligning marks made before
disassembly.
5. Repeat Steps 1-3 to install bearing caps on outer
yoke.
6. Seat all bearing caps against snap rings by
supporting cross shaft and tapping on each
corner as shown.
7.8
Continually check for free
7. When installation is complete, Yokes must pivot
freely in all directions without binding. If the joint is
stiff or binding, tap the yoke lightly to center the
joint until it pivots freely in all directions.
FRONT GEARCASE
REMOVAL
1. Stop engine, place machine in Park and set
parking brake.
2. Loosen right front wheel nuts slightly.
3. Elevate and support
footrest/frame area.
CAUTION: Serious injury may result if machine tips
or falls. Be sure machine is secure before beginning
this service procedure. Wear eye protection when
removing and installing bearings and seals.
4. Remove right wheel nuts and wheel.
5. Remove the front brake caliper and safely
suspend the brake caliper from the frame with a
piece of wire.
machine under