Remove the crankcase gallery plug and insert the oil pressure adapter. Lift the steering wheel up and remove the four fasteners that retain the pivot tube. All information contained within this publication is based on the latest product information at the time of publication. Bearing, Ball Gear, 44T Collar Sleeve, Input Shaft 109. Rotate the engine so the cylinder is facing down. If necessary, clean with soapy water and dry with low pressure compressed air.
Install the valve cover and the four T40 bolts. Inspect the ring gear for chipped, broken, or missing teeth. Install spider jamb nut onto stationary shaft threads. Reinstall the lower shock bolts to hold the trailing arms up during the rest of the removal procedure. Refer to steps 11-13 of the Steering Shaft Bearing Replacement, page 8. Dispose of used oil and filter properly. Adjust the beam to the desired position by loosening or tightening the three T-25 adjustment screws and moving the lamp to the appropriate height.
Install steering wheel cap and field test steering operation. Apply Loctite® 648 evenly to bushing bore in the cover. Remove the clutch center distance tool. Ensure that static has been discharged by touching a ground source such as the engine or frame. Remove installation tool and clutch sheave from puller.
Using an appropriate arbor press, properly support the water pump housing and press out the water pump shaft from the impeller side. The compressed springs on the shift rail may pop off causing eye or face injury. Rinse plug wells with water and dry with compressed air. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. It has Fox shocks, super atv front and back curved a-arms and trailing arms, roof, light bar , front and back windows , extended side doors , super atv front bumper , rock sliders ,Polaris 3500lb winch, extended fenders right front one missing a chunk, rear view mirror, just installed a radio and 4 6. Visually inspect each camshaft journal for scoring, wear or damage. Install the right rear lower shock bolt and new nut.
Install the fuel tank vent line onto the tank fitting. Remove four Torx T40 screws retaining the rear floor and remove the rear floor. Slowly lift up and remove the shock rod assembly from the shock body. Align the front transmission mounting holes with transmission joint bracket mounting holes on engine. Install the tilt shock and torque fastener to specification. Use only the designated pry points on the transmission.
Engine Oil Drain Plug: 12 ft-lbs 16 Nm 2. Remove the eleven M6 and two M8 upper pump. This will aid in assembly and maintains clutch balance. Refer to Cooling System Bleeding Procedure, page 3. Mark the drive belt direction of rotation so that it can be installed in the same direction. Inspect the stabilizer bar for straightness. Crankcase Drain Plug: 12 ft-lbs 16 Nm 3.
Thoroughly clean the bore of the side gear and check for any unwanted burs. Remove the upper radiator hose from the radiator. Connect the negative - battery cable to the battery and install the seat. If needed, remove the drain from the baffle box during inspection. Torque bolts to 8 ft-lb 11 Nm 10.
Wipe the pivot tube clean of any excess Loctite ® 16. Remove the front wheel hub assembly. Reinstall the two screws retaining the air box assembly. If the light flashes, the sensor is good. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. Clean both transmission case halves thoroughly. Bend both ends of cotter pin around end of spindle in different directions.