Polaris 2005 Sportsman MV7, Service Manual

Page: 199 / 312

FINAL DRIVE
7.13
K
L
16. Remove the input cover (M), bearing (N), and the
pinion gear (O). Inspect the pinion gear (O) for
chipped, broken, or missing teeth. Replace the
input cover O--ring.
M
N
O
17. Inspect the output shaft bushing. Replace as
needed. Clean the inside surfaces of both
gearcase halves.
18. Remove and replace the O--rings and seals from
the assembly.
FRONT GEARCASE
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. While rotating bearings by 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 pinion shaft, bearing, and input cover with
new o-ring and torque bolts to 14 ft. lbs (19 Nm).
Input Cover Bolts Torque:
14 ft. lbs. (19 Nm)