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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 39

6.12

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

19. Lift and maneuver transmission to free drive shaft

coupler.

20. Maneuver transmission until it can be removed from

the unit. Use care not to damage coolant lines.

21. Inspect transmission, brakes, suspension and track

for excessive wear. Check bearings for excessive
movement or rough feeling. Replace if necessary.

Inspection

Remove drain plug and drain transmission oil into
suitable container.

Remove snap ring, spacer washer, and brake disc.

Remove shift arm assembly.

Remove plug, spring and ball.

Remove case bolts.

Tap cases apart with soft faced hammer in the
reinforced areas.

Remove shaft and gear assembly from case by
tapping with a soft faced hammer evenly on end of
shafts.

Remove output gear assembly and chain. Mark chain
direction for reference during reassembly. Inspect
gear teeth for damage. Inspect chain for worn,
cracked, or broken link plates.

Remove shift fork shaft from gear cluster. Inspect
surface of fork for wear or bending.

10. Remove chain from input and reverse shaft. Inspect

gear teeth for damage. Inspect chain for worn,
cracked, or broken link plates.

11. Inspect dog gears and slots in mating gears closely.

Rounded edges will cause gears to disengage under
load. Replace both dog gear and mating gear if edge
of dog and/or slot is rounded. Inspect gears for
chipped, cracked, or broken teeth.

SHIFT ARM ASSEMBLY

REVERSE SWITCH

PLUG

SPRING

BALL

DIPSTICK

OUTPUT GEAR

6.13

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

12. Gear, shaft, and chain cluster assembly shown.

Low gear output power flow.

High gear output power flow.

Reverse output power flow.

INPUT SHAFT

LOW/RVS SHAFT

OUTPUT SHAFT

6.14

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Input Shaft Inspection

Inspect bearings to verify they roll smoothly with no
flat spots.

Remove bearings using a bearing splitter and press.

Discard seals and thrust washers. Replace with new
parts.

Inspect gear and input shaft teeth for rounded edges
and abnormal wear. Replace parts with new where
applicable.

Inspect engagement dog and sprocket engagement

tabs. Verify no edge rounding exists. Replace parts if
engagement tabs are rounded-off.

Inspect needle bearing cages and rollers. Verify
cages are not cracked and rollers are free from flat
spots.

When installing a new bearing, press on, or support
inner race while pressing bearing on to shaft.

Lubricate needle bearings and splines with
recommended gearcase engine oil lubricant.

Low / Reverse Shaft Inspection

Press bearing from end of shaft using a press and
bearing separator.

Closely inspect drive dogs. Replace gear and mating
gear if rounded, chipped or broken.

Inspect needle bearings for wear or cracks on cage.
Shiny spots on cage indicate wear and the bearing
should be replaced. Inspect shaft and thrust washers
for galling or wear. Always replace snap rings if
removed.

BEARING

THRUST WASHER

LOW GEAR

INPUT SHAFT

RVS SPROCKET

SNAP RING

ENGAGEMENT DOG

SPROCKET

NEEDLE BEARING

THRUST WASHER

SNAP RING

BEARING

SEAL

BEARING

SNAP RING

THRUST WASHER

NEEDLE BEARING

THRUST WASHER

ENGAGEMENT DOG

GEAR

SNAP RING

THRUST WASHER

NEEDLE BEARING

GEAR

SHAFT

GEAR

THRUST WASHER

SNAP RING

6.15

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Output Shaft Inspection

Remove bearings using bearing splitter and press.

Inspect bearings to ensure they roll smoothly with no
flat spots.

Discard seal and spacers. Replace with new parts.

Inspect gear and spline teeth for rounded edges and/
or abnormal wear. Replace parts as required.

Shift Drum Inspection

Remove the detent cam, spring and shaft. Discard o-
ring and replace with new part.

Check condition of key-way and key. Inspect
indicator, spring legs and detent areas for wear.
Replace parts as required.

Shift forks can be removed from shift drum by moving
shift fork to the end of it’s travel and aligning with the
corresponding hole in the shift drum. Press dowel pins
into inner shift drum. Discard pins and replace with
new.

Inspect shift forks for abnormal wear and tear.
Replace if unevenly worn.

Inspect shift drum tracks for damage. Replace drum
if any damage is found.

When installing shift forks, press dowel pins up to
.100



(2.5mm) below top of bore. Verify pins do not

bottom-out on shift groove.

Locate spring in retainer slot as shown in illustration.
Arm of shift index must be positioned between both
ends of spring.

NOTE:

The spring must be pre-loaded upon

installation. Refer to illustration.

BEARING

SPACER

47T GEAR

SHAFT

41T GEAR

SPACER

BEARING

SEAL

KEY

SHIFT INDEX

SPRING

FORK

SHIFT DRUM

SHIFT SHAFT

O-RING

DOWEL PIN

CAUTION

Wear protective eye wear when installing spring.

SPRING TABS

SHIFT INDEX

SHAFT MUST BE IN PLACE
WHEN INSTALLING SPRING

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