Middle Gearcase (6X6); Removal; Disassembly And Inspection - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

FINAL DRIVE

MIDDLE GEARCASE (6X6)

Removal

1. Place ATV on a level surface and place transmission
in 'PARK'.
2. Loosen both middle wheel nuts.
3. Loosen both middle center hub nuts.
4. Lift and safely support rear of ATV so that the wheels
are off the ground.
5. Remove both wheels and center hub nuts.
NOTE: Hub removal is not required to remove
CV shafts.
6. Remove both upper hub carrier bolts from the A-arm.
Tilt carriers outward and remove both CV shafts.
7. Remove the cross pin (if installed) from the
transmission yoke and pull vent line off the gearcase.
8. Remove the cross pin from the rear gearcase
propshaft yoke.
9. Remove the upper, lower and frame bolts from the
gearcase mounts.
10. Raise the output end of the gearcase upward in
order to remove the rear propshaft yoke. Pull
gearcase back and out the side of the frame. Some
prying and tapping with a soft-face hammer may be
required. Use care not to damage other components.
7.40

Disassembly and Inspection

1. Drain and properly dispose of used oil.
2. Remove the gearcase housing cover bolts and the
gearcase housing cover. Use the pry points (arrows)
to loosen the cover.
3. Remove the ring gear (arrow) from the gearcase
housing cover.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.