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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 38

6.8

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

20. Replace the top sprocket retaining nut.

21. Install cotter pin and bent the ends around the

jackshaft end.

22. Install the lower sprocket retaining bolt.

23. Release the parking brake.

24. Adjust the chain tensioner by hand and back off 1/4

turn.

25. Lock the adjuster lock nut.

26. Install the chaincase cover and fasteners.

27. Remove the fill cover and fill chaincase to the

appropriate level.

28. Check for leaks.

29. Adjust track tension to the specified tension.

= T

Top Sprocket Nut: 62 ft.lb. (84 N-m)

= T

Bottom Sprocket Bolt: 19 ft.lb. (26 N-m)

= T

Chaincase Cover Bolts: 10 ft.lb. (13.5 N-m)

6.9

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

DRIVESHAFT AND JACKSHAFT

Assembly View

Driveshaft / Jackshaft Fastener Torque

A = 12 ft.lbs. (16 Nm)

B = 15 - 17 ft.lbs. (21 - 23 Nm)

C = 28 - 30 ft.lbs. (38 - 41 Nm)
(Chaincase Mounting Fasteners)

Seal Sleeve / O Ring Installation

The o-rings and seal sleeves must be installed as shown
in the illustration below to prevent chaincase oil leaks.
Verify the o- ring sits inside the sleeve.

DRIVEN CLUTCH

GASKET

LUBRICATION FLANGE

BEARING FLANGE

BEARING

SPEEDOMETER FLANGE

GASKET

OFFSET FLANGE

SPEEDOMETER DRIVE KEY

DRIVESHAFT ASSEMBLY

SEAL SLEEVE

O RING

BRAKE DISC

SNAP RING

JACKSHAFT

KEY

SPACER WASHERS

SPACER

SPACER WASHERS

SEAL SLEEVE

O RING

6.10

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Jackshaft Removal

Remove the drive belt.

Remove the driven clutch. Note of the placement of
the washers.

Drain the chaincase fluid.

Remove the chaincase cover.

Remove the cotter pin on the upper sprocket.

Apply parking brake.

Remove the upper sprocket nut.

Remove the lower sprocket retaining bolt.

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.

13. Remove the jackshaft assembly from the brake disc

and chassis by tapping on the end of the jackshaft with
a soft face hammer.

14. This will also remove the o-ring and seal.

15. Inspect jackshaft in bearing contact area. If diameter

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

Jackshaft Installation

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

Insert the jackshaft assembly through the brake disc.
and install a new o-ring and seal sleeve. Push
jackshaft through chaincase.

Remove the jackshaft installation tool.

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

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

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.

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

Remove the jackshaft alignment tool from chaincase.

Install jackshaft flangette and bolts. Align grease hole
in bearing with hole or fitting in flangette. Torque nuts
to 11 ft-lb (15 N-m).

10. Place the same amount of washers on the drive clutch

end of the jackshaft.

11. Install the driven clutch, spacer, and washers and

torque the retaining bolt to 17 ft-lb (23 N-m).

12. Install the belt.

Driveshaft Removal/Installation

Remove the drain plug and drain the chaincase fluid.

Replace the chaincase drain plug.

Remove the exhaust system.

Remove the chaincase cover.

Loosen the tensioner.

Remove the lower sprocket bolt and washer.

Shut off the fuel valve if equipped.

Remove the speedometer drive housing.

Remove the rear suspension.

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

removed, remove the drive shaft.

11. Assemble in reverse order.

= T

Drain Plug: 8 ft-lb (11 N-m)

6.11

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

WIDETRAK GEARCASE

Removal

Hood can be removed to prevent damage. Mark hood
hinges for ease of alignment when reassembling unit.

Turn off fuel valve and remove battery.

Move oil tank to gain access to gearcase.

Remove muffler springs and muffler from unit.

Remove the brake caliper from the gearcase cover.
Secure the caliper up and away from gearcase
without binding the brake fluid hose.

Note location of shift linkage on transmission to
assure proper location during reassembly. Remove
cotter pin, washers, and pin from transmission arm.

Remove brake light wire connector from sensor.

Loosen rear idler wheels and bolts.

Loosen jam nuts on adjustment bolts on both sides.
Back out adjustment bolts to allow rear idler assembly
to come forward, relieving track tension.

10. Tighten idler wheel bolts so that spacers on shafts do

not rotate and lose alignment.

11. Remove carrier shaft bolts, and front and rear

suspension bolts from both sides.

12. Place a protective mat on the floor. Tip unit onto right

side and remove suspension.

13. Loosen and remove three bolts and nuts retaining

angle drive housing and flangette.

14. Remove angle drive housing, adaptor key, flangette,

gasket, and bearing from drive shaft and tunnel.

NOTE: It is not necessary to remove speedometer
cable from angle drive. Replace adapter key any time
drive train assembly is serviced.

15. Remove the driveshaft assembly from the tunnel.

16. Tip machine back onto floor.

17. Remove bolt retaining rear of bumper to foot rest, and

muffler mount.

18. Remove three transmission retaining bolts. Note all

alignment shim quantities and locations for
reassembly.

NOTE: Retaining bolts have to be held in place from
underside while removing nuts. The lower front bolt
cannot be removed at this time. It must be lowered to
the drive sprocket.

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