Polaris Sportsman 850 - Front Gearcase Removal; Installation; Non-Eps; Front Gearcase Removal (Non-Eps Models)

7
7.19
FRONT GEARCASE REMOVAL / INSTALLATION
NON-EPS
FRONT GEARCASE REMOVAL (NON-EPS
MODELS)
1. Stop engine and place gear selector in Park.
CAUTION
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
procedure. Always wear eye protection.
2. Raise and support the front of the vehicle. Remove
the front wheels.
3. Remove both front drive shafts from the front
gearcase.
4. Remove the front propshaft from the front gearcase
input shaft.
5. Disconnect the wire harness above the front
gearcase and remove the plastic tie strap retaining
the wires to the frame.
6. Remove and discard the cotter pins
q
and nuts
w
from each tie rod end at the steering post frog.
7. Remove the (2) bolts retaining the lower steering
post bracket to the front gearcase.
8. Remove the bolts and flange nuts retaining the
steering post assembly plate to both sides of the
frame.
9. Remove the front cover and remove the (2) fasteners
retaining the upper steering post bushing bracket.
10. Lift the steering post assembly up from the front
gearcase. Position the steering post toward the
center of the vehicle to allow enough room for
gearcase removal.
FINAL DRIVE