Snowmobile Polaris (2006 year). Manual - part 48
8.18
FINAL DRIVE
TRANSMISSION ASSEMBLY
Lubricate all parts before assembly with Premium Synthetic
Chaincase Lubricant.
1.
Install chain on input and reverse shaft.
2.
Add output gear assembly with chain.
3.
Add shift fork assembly.
4.
Install entire assembly in case half.
5.
Apply 3 BondE 1215 Sealant to case halves.
6.
Install outer case half and replace brake cable bracket.
Torque bolts in three steps to 8-10 ft. lbs. (11-14 Nm)
using a criss-cross pattern. Remove dowel from tensioner
and install access plug (where applicable).
7.
Install seals, shift arm, brake disc and caliper. Install
detente ball, spring, and spring guide. Fill with 20 ounces
(600cc) Polaris Premium Synthetic 0W-40 Oil.
TRANSMISSION INSTALLATION
1.
Tip unit onto right side.
2.
Insert track in unit, making sure direction of rotation is
correct.
3.
Place drive shaft in unit, aligning drive sprockets and track
drive lugs.
4.
Install lock collar, flangette, bearing, gasket, and flangette
on drive shaft, positioning bearing flush with end of drive
shaft.
5.
Lightly tighten set screws to hold bearing in place.
6.
Align flangette holes with tunnel.
7.
Replace adaptor key in drive shaft. Install angle drive
housing aligning adaptor key with angle drive.
8.
Install nuts and finger tighten.
9.
Tip machine onto its left side.
10. Replace O-rings on input and output shafts. Apply Polaris
All Season Grease to drive shaft coupler splines.
11. Reinstall transmission, using care not to damage coolant
hoses. Be sure transmission shift linkage is properly
located.
12. Install lower front mounting bolt (3) before coupling to
shaft. Once bolt is started into transmission housing, align
coupling with drive shaft and jack shaft splines. Keep
transmission flat and lower gradually to prevent binding of
couplers.
13. Install remaining transmission mounting bolts. Reinstall
shim washers in original positions and tighten bolts
securely.
NOTE: Proper transmission/jackshaft alignment is
critical for bearing service life. Use a standard nut
and flat washer for initial installation of
transmission, and install new mounting hardware
after jackshaft alignment is complete.
14. Tip machine onto its right side.
15. Loosen set screws and seat drive shaft in transmission
coupler stub shaft. For ease of assembly, make sure track
has no pressure against drive shaft.
16. Tighten nuts retaining angle drive housing to tunnel.
Torque to specification.
17. Reinstall suspension inside track and align with tunnel
mounting holes.
18. Install and hand tighten suspension bolts (1).
19. Install front carrier shaft assembly inside track and mount
to tunnel with bolts. Hand tighten bolts.
1