Polaris RANGER 1000 2020 - Chapter 8 Final Drive

8
9850045 R01 - 2020-2021 RANGER 1000 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
FINAL DRIVE SPECIFICATIONS (2020) . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . . 8.3
FINAL DRIVE SPECIFICATIONS (2021+) . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . 8.3
REAR HUB IDENTIFICATION.. ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . . 8.4
FRONT BEARING CARRIER SERVICE. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. 8.5
BEARING CARRIER REMOVAL / INSPECTION. .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . . 8.5
BEARING REPLACEMENT . . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . 8.7
BEARING CARRIER INSTALLATION . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . . 8.8
PROP SHAFT SERVICE .. .. .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... 8.11
PROP SHAFT SERVICE. .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . 8.11
FRONT PROP SHAFT SERVICE (CREW) . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ..8.12
REAR PROP SHAFT SERVICE (CREW) . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. .8.14
PROPSHAFT U-JOINT SERVICE . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .8.16
PROPSHAFT U-JOINT DISASSEMBLY . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ..8.16
PROPSHAFT U-JOINT ASSEMBLY . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . ..8.17
FRONT GEARCASE SERVICE 2020 MODELS . . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ..8.19
FRONT GEARCASE ASSEMBLY VIEW . . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .8.19
FRONT GEARCASE REMOVAL . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . ..8.20
FRONT GEARCASE DISASSEMBLY / INSPECTION .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . ..8.21
FRONT GEARCASE ASSEMBLY . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .8.24
FRONT GEARCASE INSTALLATION . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... .8.26
FRONT GEARCASE SERVICE 2021+ MODELS . ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... .8.28
FRONT GEARCASE ASSEMBLY VIEW . . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .8.28
FRONT GEARCASE REMOVAL . .. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... ... . .. . ..8.29
FRONT GEARCASE DISASSEMBLY (NON-ADC) . . .. . .. . .. . .. . ... .. .. . .. . .. . ... ... ... . .. . .. . ... . .. . ..8.31
FRONT GEARCASE INSPECTION . . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .8.34
FRONT GEARCASE ASSEMBLY (NON-ADC). ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ..8.36
FRONT GEARCASE INSTALLATION . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... .8.39
FRONT GEARCASE VENT LINE ROUTING.. . .. . .. . ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . ..8.42
FRONT DRIVE OPERATION / TROUBLEHSOOTING . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .8.43
ALL WHEEL DRIVE (AWD) OPERATION. .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. .8.43
ALL WHEEL DRIVE (AWD) DIAGNOSIS . . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. . .. . .. . .. . ... ... . .8.44
REAR BEARING CARRIER SERVICE . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. .8.46
REAR BEARING CARRIER INSPECTION. .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .. . ... . .. . .. . .. . ... ... ... . .. . ..8.46
REAR BEARING CARRIER REMOVAL . . .. . .. . .. . .. . .. . ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . .8.46
REAR BEARING CARRIER BEARING REPLACEMENT. . .. . .. . ... ... .. .. . .. . .. . ... ... ... . .. . .. . .. . ...8.47
REAR BEARING CARRIER INSTALLATION.. . .. . ... ... ... . .. . .. . .. . ... . .. . .. . .. . .. . .. . .. .. . .. . .. . .. . .8.48
REAR DRIVE SHAFT SERVICE ... . .. . .. . .. . .. . ... ... . .. . .. . ... ... . .. . .. . .. . .. . ... . .. . .. . .. . .. . ... .. .. .8.50
REAR DRIVE SHAFT REMOVAL . .. . .. . ... . .. . .. . .. . .. . ... ... . .. . .. . ... . .. . .. . .. . .. . .. . ... . .. . .. . .. . .8.50
REAR DRIVE SHAFT INSTALLATION. . ... .. .. . .. . .. . .. . ... ... . .. . .. . .. . . .. . .. . .. . .. . .. . ... . .. . .. . .. . .8.51