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POLARIS OFF-ROAD VEHICLES

HELP CENTER

4/23/2020
VIDEO: RZR Pro XP and RZR Pro XP 4 Rear Halfshaft Service

Required tools

Always wear safety glasses and nitrile gloves when servicing your Polaris RZR. To service a rear halfshaft on your model year 2020 RZR Pro XP or RZR Pro XP 4, follow these steps:

1. Place the vehicle in PARK.

2. Carefully pry the hub cap off the wheel with a flat screwdriver to access the castle nut.

3. Remove cotter pin from the castle nut with side cutters and discard.

4. Loosen the castle nut with a 30mm socket.

5. Loosen the lug nuts with a 19mm socket but do not remove.

6. Safely elevate the vehicle. Refer to your Owner’s Manual for proper lifting techniques.

7. Remove the lug nuts and set aside. Then remove the wheel.

8. Remove the castle nut and washer and discard. Caution: The castle nut, Belleville washer and cotter pin are not reusable.

9. Move the brake line retainer out of the way.

10. Using an 18mm socket and wrench, remove the upper radius rod mounting fastener, nut and washer from the bearing carrier. Swing the radius rod down and out of the away. Discard the fastener and nut.

11. Using an 18mm socket and wrench, remove the lower radius rod outer mounting fastener, nut and washer from the bearing carrier. Swing the radius rod down and out of the away. Discard the fastener and nut.

12. Carefully push the halfshaft out of the wheel hub splines and remove from the hub assembly. Use a commercially available 2-jaw puller with a minimum 3-ton capacity. Caution: The puller legs must be hooked to the wheel hub and not the brake rotor. Do not use any forms of heat to remove the halfshaft.

13. With a short, sharp jerk, remove the halfshaft from the transmission splines.

14. Thoroughly clean the splines of the hub with a contact or brake cleaner solvent. Use a wire brush or pick.

15. If the halfshaft is being reused, replace the transmission-side circlip and clean the splines of the halfshaft with a contact or brake cleaner solvent. Use a wire brush or pick.

16. Apply anti-seize to the transmission-side splines.

17. Install the halfshaft into the transmission.

18. Place a shop rag or oil-absorbent mat over the brakes to prevent contamination.

19. Apply Loctite® SF 7649 aerosol spray or brush-on primer to the splines of the hub only. Allow it to dry for at least 90 seconds. Warning: Do not inhale Loctite® Primer. Follow all directions and safety precautions on the product label.

20. Apply Loctite® 680 on the leading edge of the halfshaft splines, and in a spiral pattern around the entire circumference of the hub-side splines on the halfshaft. Caution: Do not allow Loctite® to contact the halfshaft threads or castle nut.

21. Install the halfshaft into the hub.

22. Install a new Belleville washer with the dome facing out. Important: The washer MUST be installed with the dome facing outward.

23. Then install a new castle nut. Torque to 180 ft-lbs (244 Nm).

24. Install a new cotter pin. If necessary, tighten the castle nut slightly to align the cotter pin hole.

25. Bend both ends of the cotter pin around the spindle in different directions.

26. Install the lower radius rod into the hub assembly. Install a new fastener, washer and new nut.

27. Install the upper radius rod into the hub assembly. Install a new fastener, washer and new nut.

28. Torque the radius rod fasteners to 52 ft-lbs (70 Nm) plus 90 degrees.

29. Reinstall the brake line retainer.

30. Position the wheel on the hub assembly and tighten the four lug nuts by hand.

31. Safely lower the vehicle until the tires begin to touch the ground.

32. Tighten the lug nuts. Torque to 120 ft-lbs (163 Nm) in a crisscross pattern.

33. Reinstall the hub cap.

34. Completely lower the vehicle. Caution: The Loctite® must be allowed to cure for at least 4 hours before vehicle use. 

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

Loctite® is a registered trademark of Henkel Corporation

Keyword(s) video , maintenance , shalf , half , rear , service