Drive Shaft And Cv Joint Handling Tips; Rear Gearcase; Removal; Disassembly And Inspection - Polaris 2007 SPORTSMAN X2 800 Service Manual

6. Install rear wheel and torque wheel nuts to specification.
80 ft.lbs. (109 Nm)
Refer to Page 7.2 for Wheel Nut Torque.
7. Grease all fittings thoroughly with Premium U-Joint
Lubricant (PN 2871551).

Drive Shaft and CV Joint Handling Tips

Care should be exercised during driveshaft removal or when
servicing CV joints. Driveshaft components are precision parts.
Cleanliness and following these instructions is very important to
ensure proper shaft function and a normal service life.
• The complete driveshaft and joint should be handled by
getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the driveshaft
joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft are
protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• The driveshaft is not to be used as a lever arm to
position other suspension components.
• Never use a hammer or sharp tools to remove or to
install boot clamps.
• Be sure joints are thoroughly clean and that the proper
amount and type of grease is used to refill when joint
boots are replaced and when joints are cleaned. Refer
to text for grease capacity of CV joints and CV joint
boots.

REAR GEARCASE

Removal

1. Place ATV on a level surface and place transmission in
'PARK'.
2. Loosen both rear wheel nuts.
3. Loosen both rear center hub nuts.
4. Lift and safely support rear of ATV so that the rear wheels
are off the ground.
5. Remove the roll pin from the rear transmission yoke and
pull vent line off the gearcase.
6. Remove both rear wheels and center hub nuts.
NOTE: Hub removal is not required to remove CV
shafts.
7. Remove both upper hub carrier bolts. Tilt hubs outward and
remove both CV shafts.
8. Remove the upper and lower bolts from the gearcase
mounts.
9. Pull gearcase out the rear of the vehicle. Some prying and
tapping with a soft-face hammer may be required. Use care
not to damage other components.

Disassembly and Inspection

1. Drain and properly dispose of used oil.
2. Remove the gearcase housing cover bolts and the gearcase
housing cover.
FINAL DRIVE
7
7.39