Front Gearcase Removal; Front Gearcase Disassembly / Inspection - Polaris RZR 900 2015 Service Manual

5. Check to make sure the coil
y
shaped insert that is pressed into the gearcase
u
cover . The top of the coil should be seated below
the U-shaped insert. The U-shaped insert controls
the pole gap. If the top of the coil is above the
surface of the U-shaped insert it raises the armature
plate, thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to
engage the AWD system. If this is found, replace the
cover plate assembly.
6. Inspect the roller surface on the inside of the ring
gear for gouging/rough spots.
o
7. Inspect the roll cage
excessive wear. If damaged, replace the roll cage
assembly.
a
8. Inspect the rollers for nicks and scratches. The
rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.

FRONT GEARCASE REMOVAL

1. Raise and support vehicle
2. Place gear selector in neutral.
3. Remove both front half shafts from the front
gearcase. See Chapter 7 – Front Half Shaft Removal,
page 7.10
9926814 R08 -
Manual
© Copyright Polaris Industries Inc.
t
is seated in the U- 4. Remove the front section of the prop shaft (see
5. Disconnect the wire harness for the front gearcase
6. Remove the vent line from the front gearcase and
7. Remove the four bolts
8. Rotate front of gearcase up so the input shaft is
assembly for cracks or
FRONT GEARCASE DISASSEMBLY /
INSPECTION
1. Drain and properly dispose of gearcase fluid.
2015-2016 RZR 900
Chapter 7 – Prop Shaft Removal, page 7.19).
and remove the harness from the retaining dart.
plug vent line fitting.
r
securing the front gearcase
to the frame.
facing down. Lift and remove the gearcase from the
front LH wheel well area and slide it out of the vehicle
above the upper A-arm.
Remove any metal particles from the drain plug
magnet.
2016 RZR S 1000 Service
FINAL DRIVE
7
7.25