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© 2018 SuperATV.com®. All Rights Reserved. Rev IN-DIF-CA-X3-002 / 004 6/25/2020
INSTALLATION INSTRUCTIONS
2753 Michigan Road • Madison, Indiana 47250 • 855-743-3427Locker: for Can-Am Maverick
Thank You For Choosing
Read instructions and view illustrations before beginning.
2x- Spider Gear Shim
Need help with your installation?
www.superatv.com
8:00am - 8:00pm EST M-Th8:00am - 7:00pm EST Friday9:00am - 2:00pm EST Saturday
1-855-743-3427
M6-1.0 x 16mm Lg. SHCS2x
M6 Flat Washer2x
M8-1.25 x 25mm Lg. SHCS6x M8 Flat Washer6x
M8-1.25 x 20mm Lg. SHCS8x
M6-1.0 x 16mm Lg.2x4x - Spring
Splined HubSplined Plate
Ring Gear Plate
Lid
ActuatorBacklash Tool
A Dial Indicator, not included, will be required.
Shim Pack
2IN-DIF-CA-X3-002 / 004
Switch
to Switch
to Actuator
Wire Harness details
Liability StatementSuperATV’s® products are designed to best fit user’s ATV/UTV under stock conditions. Adding, modifying, or fabricating any factory or aftermarket parts will void any warranty provided by SuperATV® and is not recommended. SuperATV’s® products could interfere with other aftermarket accessories. If user has aftermarket products on machine, contact SuperATV® to verify that they will work together.Although SuperATV® has thousands of satisfied customers, user should be aware that installing lift kits, long travel, or suspension kits, tires, etc. will change the ride of machine and may increase maintenance and part wear. Operating any off-road machine while, or after, consuming alcohol and/or drugs increases risk of bodily harm or death. No warranty or representation is made as to this product’s ability to protect user from severe injury or death. SuperATV® urges operators and occupants to wear a helmet and appropriate riding gear at all times.By purchasing and installing SuperATV® products, user agrees that should damages occur, SuperATV® will not be held responsible for loss of time, use, labor fees, replacement parts, or freight charges. SuperATV®, nor any 3rd party, will not be held responsible for any direct, indirect, incidental, special, or consequential damages that result from any product purchased from SuperATV®. The total liability of seller to user for all damages, losses, and causes of action, if any, shall not exceed the total purchase price paid for the product that gave rise to the claim.SuperATV® will warranty only parts provided by SuperATV®. Any damage or problems with OEM housings, bearings, seals, or other manufacturers’ products will not be covered by SuperATV®. SuperATV® parts and products are not warrantied if item was not installed properly, misused, or modified.Installing, adding, modifying, or fabricating any factory or aftermarket product to your ATV/UTV may violate certain local, state, and federal laws. Be advised that laws vary depending on town, city, county, state, etc. Use of certain products on public streets, roads, or highways may be in violation law. The Buyer is solely and exclusively legally and personally responsible for any violation of the law by the installation or use of the product. You must abide by all local, state, and federal laws, including but not limited to vehicle safety, traffic laws, and ordinances. It is your responsibility to know the laws and how they apply to you. The Buyer is responsible to fully understand the capability and limitations of his/her vehicle according to manufacturer specifications, warnings and instructions and agrees to hold SuperATV® harmless from any damage resulting from failure to adhere to such specifications, warnings and/ or instructions. The Buyer is also responsible to obey all applicable federal, state, and local laws and ordinances when operating his/her vehicle while using this product, and the Buyer agrees to hold SuperATV® harmless from any violation thereof.
to 12V Power and ground
“+” “-”
3IN-DIF-CA-X3-002 / 004
Removal
remove Lower A-Arms from Knuckles
(driver)
remove Axles
unbolt Actuator, disconnect Shaft and remove Front Differential
- disconnect Shocks and Sway Bar Links from Upper A-Arms- secure Upper A-Arms up and out of way- let Lower A-Arms hang
(passenger)
remove Upper A-Arm hardware from one side only
4IN-DIF-CA-X3-002 / 004
Maverick Trail Removal
unbolt Shock
unbolt Sway Bar Link unbolt Axle
unbolt Caliper
remove Hub / Disc assembly
disconnect Lower A-Arm
remove Axle
disconnect Tie Rod
repeat steps for passenger side
5IN-DIF-CA-X3-002 / 004
Maverick Trail Removal con’t
remove 4 Differential bolts
unbolt Bumper bolts
unbolt Bumper bolts
6IN-DIF-CA-X3-002 / 004
Maverick Trail Removal con’t
(passenger) front
unbolt Shaft from Differential
remove Differential from machine
to keep Front Shaft from disconnecting from Rear Shaft, keep hold of Front Shaft when removing Differential
7IN-DIF-CA-X3-002 / 004
remove Lid
separate Clutch Pack from Ring Gear
loosen (8) bolts on Clutch Pack
8IN-DIF-CA-X3-002 / 004
remove (2) countersunk screws from Clutch Pack
remove components shown
do not use impact wrench
9IN-DIF-CA-X3-002 / 004
replace stock plastic Shims with provided Spider Gear Shims
remove Snap Ring from one end
pull Pin out
do not replce if OE Shims are metal
2x- Spider Gear Shim
10IN-DIF-CA-X3-002 / 004
install provided Splined Plate
install provided Splined Hub
11IN-DIF-CA-X3-002 / 004
secure Ring Gear Plate to OE Carrier Half with hardware shown
install Ring Gear Plate to Ring Gear with hardware shown
apply thread locker to all hardware shown and do not use impact wrench when installing
torque screws to 17ft/lbs
torque screws to 70in/lbs
8x - M8 x 20mm
M6 x 16mm
2x
ALLOW THREAD LOCKER 45 MINUTES TO SET
12IN-DIF-CA-X3-002 / 004
remove Ring
install OE Shim
13IN-DIF-CA-X3-002 / 004
place Ring Gear Plate/OE Carrier Half assembly onto Lid
Reinstall Lid and check backlash; see following page and/or service manual.
- If backlash is correct, remove Lid and Ring Gear Plate.- Reinstall Ring making sure that Shim stays in place.
- If backlash setting is incorrect, remove components and replace OE Shim with provided Shim(s).
- Reassemble components and re-check backlash.- Repeat until correct backlash setting is achieved.- Once backlash is correct, remove Lid and Ring Gear Plate.- Reinstall Ring making sure that Shim(s) stay in place.
- Remove (THIN) Shim if backlash measurement is below .1mm (.004”)- Add (THICKEN) Shim if backlash measurement is above .25mm (.01”)
14IN-DIF-CA-X3-002 / 004
Backlash ToolDial Indicator
- Place Tool at end of Gear.- Place tip of Dial Indicator into dimple.- Gently move Tool back and forth;
note result.- Rotate Gear 1/2 turn and check
backlash again; note result.- Rotate Gear 1 turn and check
backlash again.
tip into dimple
Gear
remove Plug
Allen Wrench or an object to keep Gear from moving.DO NOT USE FORCE.
- If backlash is correct, remove Lid and Ring Gear Plate.- Reinstall Ring making sure that Shim stays in place.
- If backlash setting is incorrect, remove components and replace OE Shim with provided Shim(s).
- Reassemble components and re-check backlash.- Repeat until correct backlash setting is achieved.- Once backlash is correct, remove Lid and Ring Gear Plate.- Reinstall Ring making sure that Shim(s) stay in place.
- Remove (THIN) Shim if backlash measurement is below .1mm (.004”)- Add (THICKEN) Shim if backlash measurement is above .25mm (.01”)
15IN-DIF-CA-X3-002 / 004
place Springs onto Lid
place Ring Gear Plate/OE Carrier Half assembly onto Lid
4x - Spring
16IN-DIF-CA-X3-002 / 004
install to machine and secure with stock hardware; torque to 40ft/lbs
(driver)
M8 Flat Washer
6 each
M8 x 25mm
secure Lid with hardware shown
front
connect vent tube
torque screws to 20ft/lbs
apply thread locker to all hardware shown and do not use impact wrench
when installing
ALLOW THREAD LOCKER 45 MINUTES TO SET
17IN-DIF-CA-X3-002 / 004
install Switch to Dash
install actuator with hardware shown
(driver)
M6 x 16mm
M6 Flat Washer
2 each
connect Wire Harness to Actuator
reinstall components removed previously; see page 3
route Wire Harness to Switch, Battery, and Actuator; see pg. 2
(driver)
18IN-DIF-CA-X3-002 / 004
- power connections can be made at OE Power Block located in area shown- remove Passenger Seat and Console Panels to access
to 12V Power and ground
“+” “-”