Snowmobile Polaris (2006 year). Manual - part 46

8.10

FINAL DRIVE

5.

Insert carriage bolts through the back side of the chassis
and install the nylock nuts loosely.

6.

Install the jackshaft alignment tool on jackshaft and torque
enough so that the jackshaft is aligned with the chaincase
bearing.

7.

Torque all chaincase retaining bolts to 20 ft-lb (27Nm).

8.

Install the track in the chassis.

9.

Install the o-ring and then the seal sleeve onto the
driveshaft.

10. Carefully guide the drive shaft through the lower bearing

of the chain case.

11. Loosely install the lower sprocket on the drive shaft with

the retaining bolt. This will keep the driveshaft from
falling through the other side.

12. Install the rear suspension.

13. Tip machine over so that it is upright.

14. Turn the fuel valve on.

15. Support the rear of the machine.

16. Center the track so that it is contacting the drive shaft

drivers correctly.

17. Install brake caliper and torque the retaining bolts to 30 ft-

lb.(41 Nm).

18. Remove the loosely placed lower gear and retaining bolt.

19. Place the upper sprocket, lower sprocket into the chain,

and install it onto the shafts in the chaincase.

20. Lock the parking brake.

21. Replace the top sprocket retaining nut. Torque to 50 ft-lb.

22. Install cotter pin and bent the ends around the jackshaft

end.

23. Install the lower sprocket retaining bolt. Torque to 19 ft-lb.

(26Nm).

24. Release the parking brake.

25. Adjust the chain tensioner by hand and back of 1/4 turn.

26. Lock the adjuster lock nut.

27. Install the chaincase cover, and torque the cover bolts to 8

ft-lb (11Nm).

28. Remove the fill cover and fill chaincase to the appropriate

level.

29. Check for leaks.

30. Adjust track tension to the specified tension. See “Track

Tension Data” on page 3.21

CHAINCASE SEAL/BEARING 
REPLACEMENT 

1.

Remove the chaincase as described above.

2.

Pry out the old seals (P,Q) from the back side of the
chaincase.

3.

Remove bearing retaining snap rings (L,U).

4.

Press out the old bearings (M,T) from the back side of the

chain case so that the bearings drop out of the front. If the
bearing pushes out hard, warm the area to expand the
chaincase bore slightly.

NOTE:  When removing always push out the bearing 
towards the snap ring side of the chaincase.

5.

Clean the chaincase.

6.

Apply Loctite 680 to the outer race of the new bearings and
press them into the chaincase from the snap ring side.

NOTE:  Press on the bearing outer race only, or 
damage may occur to bearing.

7.

Replace the snap rings (L,U).

8.

Press in new seals (P,Q) in the back of the chaincase until
the outer edge of the seal is flush with the chaincase
shoulder.

8.11

FINAL DRIVE

DRIVE TRAIN

JACKSHAFT EXPLODED VIEW

A

B

D

C

E

F

AA

Q

P

O

N

M

L

K

J

I

H

G

X

W

V

U

T

S

R

Z

Y

Table 8-8: Jackshaft

ITEM

DESCRIPTION

TORQUE SPECIFICATION / NOTES

A

Chaincase

7.92, 8.37, 8.47

B

O-ring

8.37 chaincase - install seal sleeve (C) first, then o-ring (B) on jackshaft
7.92 chaincase - install o-ring (B) first then seal sleeve (C) on jackshaft.

C

Seal

D

Brake Disk

Minimum thickness = .193” (4.9mm)

E

Retaining Ring

included on jackshaft

F

Jackshaft

G

Bulkhead area

H

Bearing

I

Flangette

J

Belt

K

Spacer

L

Washers

M

Driven clutch retaining bolt

17 ft-lb (23Nm)

N

Driven Clutch

O

Washers

Note the placement

P

Flangette Nuts

11 ft-lb (15Nm)

Q

Driveshaft Flangette Carriage Bolts

R

Nylock Nut

11 ft-lb (15 Nm)

S

Speedo Pick Up (Speed Sensor)

T

Speed Sensor Bolt

5 ft-lb (7Nm)

U

Speedo Pick Up Housing

V

Speedo Pick Up Gasket

8.12

FINAL DRIVE

JACKSHAFT REMOVAL

1.

Remove the drive belt (J).

2.

Remove the driven clutch (N) and make note of the
placement of the washers (O).

3.

Drain the chaincase fluid.

4.

Remove the chaincase cover.

5.

Remove the cotter pin on the upper sprocket.

6.

Apply parking brake.

7.

Remove the upper sprocket nut.

8.

Remove the lower sprocket retaining bolt.

9.

Loosen the chain tensioner.

10. Remove the upper and lower sprockets and chain from

chaincase.

11. Release the parking brake.

12. Remove the bearing flange on the driven clutch side (I).

13. Remove the jackshaft assembly (E,F,H) from the brake

disc (D) and chassis by tapping on the end of the jackshaft
(F) with a soft face hammer.

14. This will also remove the o-ring (B) and seal (C).

15. Inspect jackshaft in bearing contact area. If diameter is

0.001" (.025 mm) less than non-contact area, replace the
jackshaft.

JACKSHAFT INSTALLATION 

1.

Install jackshaft installation tool PN 2871296 onto the
threads of the jackshaft.

2.

Insert the new jackshaft assembly through the brake disk
and install a new seal (C) and o-ring (B).

3.

Remove the jackshaft installation tool.

4.

With the jackshaft through the chaincase, install the
jackshaft alignment tool PN 2871535 and secure with the
flat washer and castle nut.

5.

Tighten the castle nut securely to ensure positive bearing
and jackshaft seating to chaincase.

6.

If shaft is not centered, tap shaft with a soft faced hammer
until centered. This will align the upper chaincase bearing
in the chaincase bore.

7.

Once the correct jackshaft alignment has been achieved,
install lock nuts on the chaincase mounting bolts and
torque them to 20 ft-lb (27Nm). 

8.

Remove the jackshaft alignment tool from chaincase.

9.

Install jackshaft flangette (I) and bolts (AA). Align grease

hole in bearing with hole or fitting in flangette. Torque
nuts to 11 ft-lb (15Nm).

10. Place the same amount of washers (O) on the drive clutch

end of the jackshaft.

11. Install the driven clutch, spacer (K), and washers (L) and

torque the retaining bolt (M) to 17 ft-lb (23Nm).

12. Install the belt.

13. Check clutch alignment See “CLUTCH ALIGNMENT

INSPECTION” on page 25.

W

Speedo Wheel Pick Up and bolt

12-15 ft-lb (8.8-11Nm)

X

Drive Shaft

7.92 chaincase - install o-ring (B) first then seal sleeve (C) on driveshaft.

 

Y

Chaincase Carriage Bolt

Z

Nylock Nut

20 ft-lb (27 Nm)

Table 8-8: Jackshaft

ITEM

DESCRIPTION

TORQUE SPECIFICATION / NOTES

8.13

FINAL DRIVE

DRIVESHAFT

DRIVE SHAFT REMOVAL

1.

Remove the side panels.

2.

Remove the intake plenum. 

3.

Remove the drain plug (1) and drain the chaincase fluid.

4.

Replace the chaincase drain plug and torque it to 8 ft-lb
(11Nm).

5.

Remove the chaincase cover (2).

6.

Loosen the tensioner (3).

7.

Remove the lower sprocket bolt and washer (4).

8.

Shut off the fuel valve if so equipped.

9.

Remove the exhaust system See “EXHAUST
REMOVAL” on page 3.16.

10. Remove the speedo drive pickup (5).

11. Remove the speedo drive housing (6).

12. Remove the rear skid See “REAR SUSPENSION

REMOVAL” on page 11.13.

13. With the sled over on its left side and the rear skid

removed, remove the drive shaft (7).

1

2

3

4

5

6

7