Reassembly / Inspection - Polaris 2007 Sportsman 500 EF Service Manual

Reassembly / Inspection

1. Replace all O-rings, seals, and worn components.
2. Press the pinion shaft seal into the pinion cover, until the
seal is flush with the sealing surface.
3. Inspect bearings on output and pinion shafts. To replace,
press new bearing on to shaft.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel.
hand, inspect for rough spots, discoloration, or
corrosion. The bearings should turn smoothly and
quietly, with no detectable up and down movement
and minimal movement side to side.
4. Install input shaft, bearing, snap ring, and input cover with
new o-ring. Torque bolts to specification.
Input Cover Bolt Torque
14 ft. lbs. (19 Nm)
While rotating bearings by
= T
5. Install the LH output hub (A) into the gearcase housing.
The output hub should spin freely.
A
6. Install the RH output hub (B) into the output cover. The
output hub should spin freely.
C
B
7. Install the rollers and roll cage into the ring gear. Insert the
rollers as the roll cage is installed.
FINAL DRIVE
A
B
7
7.17