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#1
10-28-2010, 12:40 PM
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RZR Front Diff
Had to rebuild a front diff on an 09 RZR. Took a couple pics just to show whats all involved with a job like this. Also there were some posts asking about how the polaris awd works. I thought these pics would help to show how the system works.
1st pic shows the ring gear and the plastic cage that commonly breaks that holds the rollers. 2nd pic shows armature plate and where it fits into the cage. Third pic shows what happens when armature plate is grabbed by magnet and rollers climb the ramp to engage onto output hubs. 4th pic shows output hub and where it fits into cage and rollers. 5th pic shows what diff looks like assembled and ready to put cover on. 6th pic shows cover with magnet setup and backlash adjusting pad. 7th pic diff is all assembled & ready to install back into rzr. 8th pic empty chassis ready for rebuilt diff. It installs very easily by putting diff on its side and sliding into frame. Once diff is in just rotate and line up propshaft to put roll pin back in. Also important is keeping prop shaft greased. Remove engine cover from behind seats and reach under clutch cover to find grease nipple on sliding yoke. I see lots of units come into the shop with drivetrain noise and by that time it needs replacement. So if you keep that greased it should prevent premature wear and tear. Hope some (or all) of this info helps you rzr owners out there as there are so many around now.  
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| The Following 11 Users Say Thank You to r_gillies For This Useful Post: | ||
'alljackedup' (10-29-2010), blastergirl21 (10-29-2010), camoman (05-06-2011), fuelinjected (10-28-2010), kevin4578 (10-28-2010), lakeracer900 (12-22-2012), LeCaptain (10-28-2010), mailman (10-28-2010), rubberdown (10-28-2010), Trizo123 (09-18-2011), vinnie (10-28-2010) | ||
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#2
10-28-2010, 01:34 PM
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Thanks for the pics! Did this diff actually require a new cage or other parts? Did you use a new plastic cage or an aluminum cage?
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2009 Sportsman 850 XP EPS, HSP Pipe, Rubberdown 2-1/2" a-arm lift, K&N, 30" zillas on 212's, 32's on Aluminum Lox, PC5, Turner Nitro's!!!! 04.5 500HO, RDC Lift Kit, Gorillas & Turners in , RDC Alum. Gas Cap & Overflow cap, RDC Bar Ends, RDC Throttle cover, HSP motor job, HSP Full Exhaust, QSC Clutch , 29.5's on RDC Alum. Swamp Lox, Rad racked, snork'd, goes real fast in the bog pit with around 46 HP!!!! rubberdowncustoms@yahoo.ca (905) 356-9181
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#4
10-28-2010, 03:08 PM
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great post. If it was mine I would have swapped out the plastic cage even though its on warranty. Probably break again just after warranty
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Current Quads - 2001 yamaha 4 stroke golf cart, 6" Jakes list, 22" Kenda Tires Current Sleds - 11 F8 SP, 2011 500 SnoPro, 2013 Indy 600 SP ES Previous Quads: 09 MudPro - 28 Backs/ITP, 2008 Prowler - 4.0 gears, 30" zillas, snorkled 2006 AC H1 - HMF, 4.0 gears, snorkled, rad-relocate, 29.5 Laws 05 AC 500 manual, 29.5 Laws, HMF, Webb Cam
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r_gillies (10-29-2010) | ||
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#5
10-28-2010, 07:19 PM
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put the billet cage in Bin muddins front diff after it gernated in the snow. works nice.
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Wild cat 1000 H.O. need I say anymore. Something Wicked This Way Comes! If you want to run with the big dogs you can't piss like a puppy All Chef's @#%you
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r_gillies (10-29-2010) | ||
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#6
10-28-2010, 07:39 PM
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yeah did my 08 last year. Grtwhthntr did it. just replaced the cage with a Holz .
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r_gillies (10-29-2010), sixthreemercury (11-01-2011) | ||
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#7
11-08-2010, 03:15 PM
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I spoke with Foster from Polaris last week and he said the plastic cages will be updated to a new zinc one in the future or as an accessory polaris will have a billet one.
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blastergirl21 (11-08-2010) | ||
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#8
09-14-2012, 12:33 PM
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I just put a 900XP diff in mine after mine exploded at Norte dame that way you get the bigger pinion bearing and get rid of the plastic cage. 850.00 from babbits
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 drink away the pain
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#9
09-14-2012, 01:32 PM
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Buddy Of Mine Had His Blow Up Too Swapped It To The Alumi One And Had No Issues
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 ~BRENDIN~ 07 800 can am outlander 27" mudzillas snorkels :) hmf pipe and optimizer 3000 lb Smittybilt winch Front A arm skid plates The deeper you're, the more fun you're having
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