UPGRADE 2015 RZR XP 1000
FRONT DIFF CARRIER
With all the needle bearings in place, you will slide the assembly back into
place. As you insert the carrier into its hole, you can cut the zip-ties off one at
Reinstall the two hold-down plates, being sure to designate the alignment pin
and ears correctly.
Reinstall the diff cover and its seven bolts. Tighten them by hand using a star
pattern like you would with an automotive wheel or a head gasket.
Replace the front differential into the frame, slide the driveshaft flange onto
the input shaft, being sure that the pin hole is clocked correctly. Install mount-
ing bolts and then drive the pin back into the flange. Reassemble your front
end in reverse of how you took it apart.
With your RZR off the jacks and on level ground, you will need to refill the
front differential. Remove the plug with a 6mm Allen socket, and then only fill it
with Polaris Demand Drive Plus until it leaks out of the fill hole. You will need a
small funnel with a filler tube to avoid making a huge mess.
Here’s an easier way
to fill the front diff.
Insert a really small
funnel into the front-diff vent line, and use
the vent line to fill the
diff until fluid starts
to creep out of the
threads of the plug.
Replace the plug and