Polaris Sportsman XP 1000 S 2020 Service Manual page 361

2. Remove the coupler from the pinion shaft by using
two pry bars in the areas shown. If the coupler is
difficult to remove, use a universal bolt-grip puller to
prevent any damage.
3. Remove the seal above the pinion shaft using a seal
puller or other suitable method (see Figure 8-27).
4. Remove the retaining ring and lift the pinion shaft
and bearing from the main gearcase (see Figure 8-
27).
NOTICE
If the pinion shaft will not lift out of the gearcase,
reinstall the coupler and tighten the retaining nut by
hand. Use two pry bars to lift the pinion shaft assembly
out.
5. Support the pinion shaft and press the bearing off the
shaft (see Figure 8-27).
6. Thoroughly clean the pinion shaft.
WARNING
Wear appropriate safety equipment while installing
bearings to reduce the risk of injury.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
7. Support the pinion shaft and carefully press the new
bearing on the shaft and install a new O-ring (see
Figure 8-27).
NOTICE
Carefully inspect the pinion shaft gear before replacing
the bearing. If the gear teeth are damaged, the shaft
must be replaced as an assembly.
8. Remove the seals from each case half using a seal
puller or other suitable method (see Figure 8-28).
9. Support the gearcase cover and press the bearing
out. Repeat this procedure on the main gearcase
half, unless the bearing came out with the ring gear
(see Figure 8-28).
NOTICE
If the main gearcase bearing is installed on the ring
gear, heat the bearing to remove it.
10. Thoroughly clean the gearcase halves.
WARNING
Wear appropriate safety equipment while installing
bearings to reduce the risk of injury.
11. Support the gearcase cover and carefully press in
the new cover bearing (see Figure 8-28). Support the
ring gear and carefully press on the new main
gearcase bearing.
FINAL DRIVE
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