7
7.73
REAR GEARCASE INSTALLATION -
TOURING
1. Install the rear gearcase by reversing the “Gearcase
Removal” procedure at the beginning of this section.
Refer to the following installation steps for torque
specifications. Gearcase Removal (TOURING
Models), page 7.64
2. Install the gearcase through-bolt mounting fasteners
and torque to specification.
NOTE
Use the longer bolts (150 mm) in the top and the
shorter bolts (125 mm) in the bottom.
TORQUE
Gearcase Mounting Fasteners:
40 ft. lbs (54 Nm)
3. Install the right rear drive shaft into the gearcase and
the upper A-arm onto the bearing carrier. Torque the
bearing carrier through-bolt fastener to specification.
TORQUE
Rear Upper A-arm to Bearing Carrier:
37 ft. lbs (50 Nm)
4. Install the left rear drive shaft and suspension
assembly. Torque the upper and lower A-arms to
specification.
TORQUE
Rear Upper & Lower A-arms to Frame:
37 ft. lbs (50 Nm)
5. Install the rear upper shock through-bolts. Torque
bolts to specification.
TORQUE
Rear Upper Shock Bolts:
30 ft-lbs (54 Nm)
6. Install the rear stabilizer bar onto the linkage rods.
Torque the linkage retaining nuts to specification.
TORQUE
Stabilizer Bar Linkage Bolts:
37 ft. lbs (50 Nm)
7. Install the propshaft coupler onto the rear gearcase
pinion shaft splines. Install the lock washer and
retaining nut.
NOTE
Orient the lock washer as shown with the tooth surfaces
contacting the nut and coupler.
8. Lock the brake lever and torque the propshaft
coupler retaining nut to specification.
TORQUE
Coupler Retaining Nut:
100 ft. lbs (136 Nm)
9. Install the rear propshaft and torque bolts to
specification.
TORQUE
Rear Propshaft Bolts:
18 ft. lbs (25 Nm)
10. Install the rear wheels and torque wheel nuts to
specification.
11. Add Polaris ATV Angle Drive Fluid to the rear
gearcase. Torque drain and fill plugs to specification.
FLUID CAPACITY
Rear Gearcase Capacity:
7.1 fl. oz. (210 ml) or to bottom of fill plug hole threads
TORQUE
Drain / Fill Plug:
14 ft. lbs (19 Nm)
FINAL DRIVE
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