Polaris General XP 2021

8
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
8.1
FINAL DRIVE
CHAPTER 8
FINAL DRIVE
GENERAL INFORMATION - FINAL DRIVE . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 8.3
SERVICE NOTES - FINAL DRIVE. .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. 8.3
SPECIAL TOOLS - FINAL DRIVE . . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . 8.3
SERVICE SPECIFICATIONS - FINAL DRIVE . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 8.3
ASSEMBLY VIEWS - FINAL DRIVE . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 8.4
PROPSHAFT ASSEMBLY VIEW - 2 SEAT.. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... 8.4
PROPSHAFT ASSEMBLY VIEW - 4 SEAT.. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... 8.5
DRIVE SHAFT ASSEMBLY VIEW . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 8.6
DRIVE SHAFT ASSEMBLY VIEW (INTL ABS MODELS) . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... 8.7
FRONT GEARCASE ASSEMBLY VIEW . . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. 8.9
GEARCASE VENT LINE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..8.10
PROPSHAFT SERVICE. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... 8.11
PROPSHAFT REMOVAL - 2 SEAT . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. 8.11
PROPSHAFT REMOVAL - 4 SEAT . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..8.12
U-JOINT DISASSEMBLY . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. .8.14
U-JOINT ASSEMBLY . . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..8.15
PROPSHAFT INSTALLATION - 2 SEAT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..8.16
PROPSHAFT INSTALLATION - 4 SEAT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..8.18
DRIVE SHAFT SERVICE - GENERAL / GENERAL 4 . . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. .8.20
FRONT DRIVE SHAFT REMOVAL . . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ..8.20
FRONT DRIVE SHAFT INSTALLATION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..8.21
REAR DRIVE SHAFT REMOVAL . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .8.22
REAR DRIVE SHAFT INSTALLATION. . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .8.23
DRIVE SHAFT / CV JOINT HANDLING TIPS . . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .8.25
OUTER CV JOINT / BOOT REPLACEMENT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .8.26
INNER PLUNGING JOINT / BOOT REPLACEMENT. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..8.28
DRIVE SHAFT SERVICE - GENERAL XP / GENERAL XP 4. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. .8.31
FRONT DRIVE SHAFT REMOVAL . . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ..8.31
FRONT DRIVE SHAFT INSTALLATION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..8.32
REAR DRIVE SHAFT REMOVAL . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .8.34
REAR DRIVE SHAFT INSTALLATION. . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. .8.35
DRIVE SHAFT / CV JOINT HANDLING TIPS . . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... .8.36
OUTER CV JOINT / BOOT REPLACEMENT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .8.37
INNER PLUNGING JOINT / BOOT REPLACEMENT. . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..8.39
BEARING CARRIER SERVICE - GENERAL / GENERAL 4 . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ..8.42
FRONT BEARING CARRIER REMOVAL / INSPECTION .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...8.42
FRONT BEARING REPLACEMENT. ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ..8.43
FRONT BEARING CARRIER INSTALLATION . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .8.44
REAR BEARING CARRIER REMOVAL / INSPECTION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..8.46
REAR BEARING REPLACEMENT . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . .8.47
REAR BEARING CARRIER INSTALLATION.. . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .8.48