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Polaris Sportsman 850 - Gearcase Disassembly; Inspection

Polaris Sportsman 850
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7.32
6. Inspect the rollers for nicks and scratches. The
rollers must slide freely within the roll cage and H-
springs.
7. Inspect the roll cage assembly for cracks or
excessive wear. If damaged, replace the roll cage
assembly.
GEARCASE DISASSEMBLY / INSPECTION
1. Drain and properly dispose of used lubricant.
Remove any metal particles from the drain plug
magnet.
2. Remove the (6) screws retaining the cover plate
assembly and open the wire retaining clip.
3. Remove the cover plate assembly from the
gearcase.
4. Remove the female (LH) output hub assembly.
Inspect the thrust bearing (A) for wear. Inspect the
output hub ball bearings, contact surfaces and
splines for signs of wear or damage.
NOTE
Excessive noises coming from the front drive on
deceleration are key indicators of burnt or broken down
front drive fluid.
5. Remove and inspect the armature plate. Refer to
“AWD Diagnosis” for detailed inspection process.
FINAL DRIVE

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