Gearcase Assembly / Inspection - Polaris 2008 RZR Service Manual

12. Remove the roll cage assembly and rollers from the clutch
housing. Use a shop towel to cover the housing in order to
retain all the rollers.
NOTE: Rollers are spring loaded. Take care not to
allow them to fall out or lose them upon removal of
the roll cage.
13. Thoroughly clean all parts and inspect the rollers (A) for
nicks and scratches. The rollers must slide up and down and
in and out freely within the roll cage sliding surfaces and
H-springs.
B
14. Inspect the roll cage assembly (B) sliding surfaces and H-
springs. The sliding surfaces must be clean and free of
nicks, burrs or scratches. If damaged, replace the roll cage
assembly.
H-Spring
15. Inspect clutch housing ring gear (C) for a consistent wear
pattern. Inspect the ring gear for chipped, broken, or
missing teeth.
16. Inspect both output hub assemblies. Inspect the bearings
and replace if needed.
Bearing
C

Gearcase Assembly / Inspection

1. As mentioned during gearcase disassembly section,
replace all O-rings, seals, and worn components.
2. Press the pinion shaft seal into the pinion cover, until the
A
seal is flush with the sealing surface.
3. If bearing replacement was required, press new bearings on
to the pinion shaft assembly.
4. Install pinion shaft, bearings, and pinion cover with new
O-ring and torque screws to 7-11 ft. lbs. (10-15 Nm).
B
Pinion Cover Screw Torque:
FINAL DRIVE
Spacer
Torque
Screws
7-11 ft. lbs. (10-15 Nm)
Thrust
Bearing
Roller
Surface
7
7.17