Adc Gearcase Piston Replacement Procedure - Polaris 2007 Sportsman 500 EF Service Manual

19. Remove the snap ring retaining the input shaft assembly.
20. Remove the input shaft assembly. Inspect the pinion gear
(1) for chipped, broken, or missing teeth. Inspect the input
shaft bearing (2) for signs of wear. Replace the input shaft
cover O-ring (3) prior to reassembly.
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21. Inspect the input shaft bushing. Replace case if worn.
ADC Gearcase Piston Replacement
Procedure
1.
3
2
2.
3.
NOTE: Never re-use o-rings. Always replace with
new.
CAUTION
This repair procedure involves the
use of compressed air. Safety glasses
or a face shield are required.
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)
AIR
ADC Piston Tool
PA-48542
Repeat procedure for the other piston. (See photo)
AIR
Remove and discard the inner and outer o-rings from the
piston assembly.
FINAL DRIVE
PA-48542
7.27
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