Installation - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

FINAL DRIVE
5. Apply Crankcase Sealant (PN 2871557) to surface of
case and install cover bolts. Install the gearcase
cover onto the gearcase housing. Torque the cover
bolts in a criss-cross pattern to specification.
Cover Bolt:
25 ft-lbs (34 Nm)
6. Install the drain plug and fill plug. Replace the drain
plug washers to ensure proper sealing after filling.
Drain / Fill Plug:
14-18 ft-lbs (19-24 Nm)
7.60

Installation

1. To install the rear gearcase, reverse the removal
procedures.
2. Pre-install the propshaft onto the transmission and
insert the roll pin. While installing the gearcase, align
the propshaft and gearcase input shaft for easier
propshaft installation. Use of anti-seize compound
on the shaft splines is recommended.
3. Torque the gearcase mounting bolts to specification.
4. Re-install CV shafts, hubs, carrier bolts, etc. and
torque to specifications.
Gearcase Mounting Bolts: 30 ft-lbs (41 Nm)
Upper / Lower Control Arm Bolt: 37 ft-lbs (50 Nm)
Wheel Nut (Aluminum): 30 ft-lbs (41 Nm) + 1/4 turn
5. Re-install gearcase vent line.
6. Refill the rear gearcase with Polaris Premium
Gearcase Lubricant (PN 2871653). Refer to the
"REAR GEARCASE LUBRICATION" procedure in
Chapter 2.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Rear Hub Nut: 80 ft-lbs (109 Nm)
Wheel Nut (Steel): 27 ft-lbs (37 Nm)