Front Gearcase Installation - Polaris Sportsman XP 1000 S 2020 Service Manual

FRONT GEARCASE INSTALLATION

1. Install the gearcase between the upper and lower A-
arms.
2. Install the vent line and the (4) bolts that secure the
front gearcase to frame. Torque bolts to specification.
TORQUE
Front Gearcase Mounting Bolts
37 ft-lbs (50 N·m)
3. Connect and route the AWD wire harness along the
frame and install a plastic tie strap to attach it to the
frame.
4. Install the steering tie rod ends into the steering
idlers. Torque nuts to specification.
TORQUE
Tie Rod End Nuts
40 ft-lbs (54 N·m)
5. Install the front propshaft onto the front gearcase
input shaft.
6. Install both front drive shafts into the front gearcase.
7. Reinstall the front gearcase drain plug with a new O-
ring and torque to specification.
8. Add the recommended amount of fluid. Maintain fluid
level even with the bottom threads of the fill plug hole.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive Fluid
Capacity:
9.3 oz. (275 ml)
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
9. Reinstall fill plug with a new O-ring and torque to
specification.
TORQUE
Front Gearcase Drain / Fill Plug
19 ft-lbs (26 N·m)
FINAL DRIVE
8
8.21