8.12
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
22. Place a 23 mm, 12 point socket over the splines of
the output shaft. Attach an Inch Pound (in-lbs) dial
indicator torque wrench to the socket. Check the
intermediate pinion shaft assembly bearing rolling
preload by rotating the output shaft both clockwise
and counter-clockwise.
Intermediate Shaft Rolling:
17-22 in-lbs (1.9-2.48 Nm)
23. A) If the torque required to rotate the output shaft is
out of specification, continue to step 24.
B) If the torque required to rotate the output shaft is
within specification, no adjustment is needed and the
transfer case reassembly is complete.
24. Remove the transfer case cover screws and the
transfer case cover.
25. After removing the cover, remove the intermediate
shaft bearing cup and shim (s) from the cover. The
bearing cup is a slip-fit.
26. A) If the rolling torque measurement from step 22
was below specification, replace the existing shim(s)
with a thicker shim or shim stack from the table
below.
B) If the rolling torque measurement from step 22
was above specification, remove or replace the
existing shim (s) with a thinner shim or shim stack
from the table below.
Shim Kit 3234560
Includes:
Quantity
.003” (.076mm)
2
.005” (.127mm)
2
.010” (.254mm)
2
.030” (.762mm)
1
27. Install selected shim(s) and slip fit bearing race into
transfer case cover. Coating shim (s) and bearing
race with Polaris All Purpose Grease may be
necessary to hold the assembly together during
installation.
28. Apply a thin coat of sealant to the case mating
surfaces.
Apply Sealant: PN 2871557
To Case Mating Surfaces
TRANSMISSION
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