Polaris Sportsman XP 1000 S 2020 - Chapter 8 Final Drive

8
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
8.1
FINAL DRIVE
CHAPTER 8
FINAL DRIVE
GENERAL INFORMATION.. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . 8.3
SPECIAL TOOLS . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . . 8.3
WHEELS . . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . 8.4
WHEEL REMOVAL . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . .. . . ... . ... . . .. . ... 8.4
WHEEL INSTALLATION . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . ... . . . 8.4
WHEEL STUDS . . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . 8.5
WHEEL STUD SERVICE . . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . 8.5
WHEEL HUBS . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. 8.8
FRONT HUB ASSEMBLY VIEW. ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... 8.8
REAR HUB ASSEMBLY VIEW . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . 8.9
FRONT BEARING CARRIER . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . ..8.10
FRONT BEARING CARRIER INSPECTION / REMOVAL .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ...8.10
FRONT BEARING CARRIER REPLACEMENT .. . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .8.11
FRONT BEARING CARRIER INSTALLATION . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . .8.12
FRONT DRIVE SHAFT. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .8.14
REMOVAL. ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ...8.14
INSTALLATION . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .8.15
FRONT PROPSHAFT . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . ..8.16
REMOVAL. ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ...8.16
INSTALLATION . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .8.16
PROPSHAFT U-JOINT SERVICE . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..8.17
PROPSHAFT U-JOINT DISASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . ..8.17
PROPSHAFT U-JOINT ASSEMBLY . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..8.18
FRONT GEARCASE REMOVAL / INSTALLATION .. . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .8.20
FRONT GEARCASE REMOVAL . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ..8.20
FRONT GEARCASE INSTALLATION . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . .8.21
FRONT GEARCASE (ADC).. . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . ..8.22
FRONT GEARCASE ASSEMBLY VIEW . . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . .8.22
OPERATION, FRONT GEARCASE (4WDC). . ... . ... . .. . . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . .8.24
DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC) .. . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..8.25
REASSEMBLY, FRONT GEARCASE (ADC) . . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .8.28
TROUBLESHOOTING, FRONT GEARCASE (ADC) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .8.31
REAR BEARING CARRIER.. . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . ..8.35
REAR BEARING CARRIER INSPECTION. .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . .8.35
REAR BEARING CARRIER REMOVAL . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ..8.35
REAR BEARING CARRIER BEARING REPLACEMENT. ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..8.36
REAR BEARING CARRIER INSTALLATION.. . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . .8.37
REAR DRIVE SHAFT .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. .8.38
REAR DRIVE SHAFT REMOVAL . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .8.38
REAR DRIVE SHAFT INSTALLATION. . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . ..8.39