Adc Gearcase Piston Replacement Procedure - Polaris A12MH46AX Service Manual

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ADC Gearcase Piston Replacement

This repair procedure involves the

use of compressed air. Safety glasses

or a face shield are required.

1. Place ADC Piston Tool PA-48542 on top of the

piston. Using moderate hand pressure, hold the tool

on top of the piston while using compressed air at the

gearcase passage (circled) to force piston up and out

of the case. (See photo)

ADC Piston Tool

2. Repeat procedure for the other piston. (See photo)

3. Remove and discard the inner and outer o-rings from

the piston assembly.

NOTE: Never re-use o-rings. Always replace with

9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual

4. Coat new piston and o-rings with a moderate amount

of white lithium grease or assembly lube. Coat the

edges of the piston cavities. Install the inner and outer

piston o-rings.

5. Place the piston in the piston cavity, aligning the pins

with the pin bosses. Using the casting and piston

marks as a guide as shown will aid pin alignment.

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