2005 Polaris Sportsman 400/500 Service Manual, Page 200Get this manual
FINAL DRIVE 18Remove and replace the Orings and seals from the assemblyL
16Remove the input cover (M), bearing (N), and the pinion gear (O)Inspect the pinion gear (O) for chipped, broken, or missing teethReplace the input cover Oring
FRONT GEARCASE REASSEMBLYINSPECTION
1Replace all Orings, seals, and worn components2Press the pinion shaft seal into the pinion cover, until the seal is flush with the sealing surface3Inspect bearings on output and pinion shaftsTo replace, press new bearing on to shaftNOTE: Due to extremely close tolerances and minimal wear, the bearings must be inspected visually, and by feelWhile rotating bearings by hand, inspect for rough spots, discoloration, or corrosionThe bearings should turn smoothly and quietly, with no detectable up and down movement and minimal movement side to side4Install pinion shaft, bearing, and input cover with new o-ring and torque bolts to 14 ftlbs (19 Nm)