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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
9/8/2023

2021+ RZR 200 EFI Axle Removal and Installation

Required Tools and Supplies
13mm Socket13mm Wrench
15mm Socket15mm Wrench
1 1/16-Inch SocketRatchet
Torque WrenchPliers
Breaker BarAnti-Seize
Flat Head ScrewdriverCotter Pin
Outer Radius Rod NutsDomed Washer
Bearing Carrier NutsCastle Nut
Compression RingSafety Glasses
Nitrile GlovesShop Towels

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RZR.

To remove and install the axle on your model year 2021 and newer RZR 200 EFI, follow these steps:

1. Park the vehicle on a flat, level surface and set the parking brake.

2. Remove the center cap from the wheel. 

3. Remove and discard the cotter pin from the wheel hub castle nut.

4. Loosen the castle nut with a 1 1/16-inch socket.

5. Loosen the lug nuts while the vehicle is on the ground with a 15mm socket with breaker bar, but do not remove them at this time.

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

7. Once safely elevated, remove the lug nuts and set aside. 

8. Remove the wheel and set aside. 

9. Remove and discard the castle nut and cone washer from the wheel hub.

10. Pull the rear hub assembly away to remove from the vehicle.

11. Remove and retain the fasteners securing the radius rods to the bearing carrier with a 13mm wrench and 15mm socket. Discard the nuts.

12. Remove and retain the three fasteners that attach the rear bearing carrier to the trailing arm with a 13mm socket and 15mm wrench. Discard the nuts.

13. Continue by pulling the bearing carrier away from the axle and trailing arm to remove from the vehicle.

14. With a short, sharp jerk, remove the axle from the axle housing.

15. Clean the anti-seize off the axle splines using a clean, dry cloth.

16. Inspect the threads and splines on the axle for nicks or burrs and replace if needed.

17. Inspect the CV boots to ensure there are no cuts, wear or damage and replace if needed. 

18. Remove and discard the compression ring on the axle with a flat-head screwdriver.

19. Install a new compression ring into the groove on the end of the axle and ensure it is fully seated. 

20. Before installing, clean any old anti-seize from the axle housing and hub assembly. 

21. Apply new anti-seize to the inboard splines on the axle.

22. Align the splines on the axle with the axle housing and push in firmly on the shaft until the compression ring is fully engaged in the housing. 

23. Reinstall three retained fasteners through the bearing carrier and loosely install new nuts.

24. Align the radius rods with the bearing carrier. Reinstall the retained fasteners from the rear of the vehicle and loosely secure with new nuts.

25. Torque the rear bearing carrier fasteners to 40.5 ft-lbs (55 Nm).

26. Torque the outer radius rod mounting fasteners to 40.5 ft-lbs (55 Nm).

27. Align the hub assembly with the splines on the axle and push the assembly against the bearing carrier until fully seated.

28. Loosely install a new domed washer, dome side out, and a castle nut.

29. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.

30. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torqueing. 

31. Once lowered, torque the lug nuts to 30 ft-lbs (40 Nm) in a crisscross pattern. Note: The wheel will need to be retorqued after the first ride following this procedure.

32. Torque the wheel hub castle nut to 80 ft-lbs (109 Nm).

33. Continue by inserting a new cotter pin, and bend around the castle nut to secure. If necessary, tighten the castle nut to align the cotter pin holes.

34. Push the dust cap onto the wheel and ensure it is fully seated.

35. Finally, lower the vehicle completely.

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.

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© 2023 Polaris Industries Inc.

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