Polaris SPORTSMAN 400 2003 Service Manual page 183

FINAL DRIVE
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected visually,
and by feel. While rotating bearings by hand, inspect
for rough spots, discoloration, or corrosion.
bearings should turn smoothly and quietly, with no
detectable up and down movement and minimal
movement side to side.
5. Clean pinion shaft and lock nut with PrimerNt
and apply red LocTitet to threads. Tighten lock
nut to specification.
6. Install pinion shaft and pinion cover plate with new
o-ring and torque bolts to 14 ft. lbs. (19 Nm).
Pinion Shaft Lock Nut
Torque
65 ft. lbs. (89.7 Nm)
Cover Bolts Torque
14 ft. lbs. (19 Nm)
Equal Shims
7. Install output shaft assembly.
7.18
The
NOTE: The same shim thickness placed behind ring
gear bearing must also be put behind the cover
button.
8. Install output shaft cover with new o-ring and
torque bolts to 14 ft. lbs. (19 Nm).
Cover Bolts Torque
14 ft. lbs. (19 Nm)
FRONT HOUSING
INSTALLATION
Fill Plug
1. To install housing, reverse removal procedure.
Use new roll pins in drive shafts.
2. Add Polaris Premium Front Housing Lubricant or
GL5 80-90 gear lube to front housing. Check drain
plug for proper torque.
Premium Front Housing Fluid
(PN 2871653) (12 oz.)
Front Housing Capacity
4.0 fl. oz. (118 ml)