Gearcase Disassembly / Inspection - Polaris Sportsman XP 1000 S 2020 Service Manual

7. Locate the rear propshaft through the rear RH wheel
well.
8. Remove the (4) bolts retaining the rear propshaft to
the rear propshaft flange and discard the bolts.
9. Slide the shaft towards the transmission and pivot the
propshaft down. Slide the propshaft off the
transmission output shaft and out from the vehicle.
10. Remove the (4) rear gearcase mounting fasteners.
11. Disconnect the gearcase breather hose from the
gearcase.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
12. Remove gearcase from chassis by lifting the
gearcase up and out the rear of the vehicle.
GEARCASE DISASSEMBLY /
INSPECTION
NOTICE
Pinion and ring gear shimming information is NOT
provided. The components are matched at the factory,
which requires special OEM tooling in order to properly
assemble and shim the gears.
In the event damage to the gears or housing requires
replacement, the entire assembly must be replaced.
1. Drain and properly dispose of used gearcase
lubricant.
2. Remove the (8) screws from the rear gearcase
cover.
3. Lift the gearcase cover off the main gearcase half
and note the shim between the cover and the ring
gear.
FINAL DRIVE
8
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