Polaris GEM E Series, Service Manual

Page: 29 / 174

DRIVETRAIN 3 - 3
November 2007 GEM Service Manual
7. Remove king pin pinch bolt and separate
control arm.
8. The inner end is held on with a spring clip.
Using a pair of short pry bars, gently force the
inner end off the differential. Take care to not
damage the splined shaft during this
procedure.
9. Make sure the spring clip is still on splined
shaft of differential and is not damaged. (If
damaged, replace.)
10. Remove the outer end of the halfshaft from the
steering knuckle assembly.
Fig 2. Halfshaft Removal
1 - Halfshaft
2 - Inner Boot
3 - Differential
4 - Pry bar(s)
INSTALLATION
1. Apply Optimol Olistamoly 2 LN 584 LO grease
or equivalent to the splines at the inner and
outer end of the halfshaft prior to installation.
2. Insert the outer end of the halfshaft into the
steering knuckle assembly.
3. Make sure the spring clip is still on splined
shaft of differential and is not damaged.
4. Install the inner end of the halfshaft over the
splined shaft on the differential. Press inward,
toward differential until spring clip snaps into
place.
5. Connect the lower control arm and install the
king pin pinch bolt.
6. Install upper front shock mounting bolt just
snug.
7. Install washer and nut on halfshaft outer end.
8. Add Loctite® 242 and torque halfshaft nuts to
65 ft-lb. and install a new cotter pin.
9. Install front tire and wheel assembly. Tighten
lug nuts to 65 ft-lb.
10. Install hubcap.
11. Lower vehicle to ground.
12. Tighten spring/shock absorber mounting bolts
to 60 ft-lb.
13. Switch master disconnect switch to ON.
CLEANING AND INSPECTION
Inspect splines and the boots on the halfshafts for
wear or damage. If worn or damaged, replace the
halfshaft as an assembly.
TORQUE SPECIFICATIONS
Description Thread Size Use
Loctite®
242
Inch-
Pounds
Foot-
Pounds
Halfshaft to steering knuckle assembly
M16 x 1.5 YES --- 65
Shock absorber lower bolt
M12 x 1.75 NO --- 60
Tie rod stud nut
M10 x 1.5 NO --- 35
Wheel lug nuts
12mm NO --- 65