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Snowmobile Polaris Two Stroke (2007 year). Manual - part 45

7.7

FINAL DRIVE/BRAKES

CHAIN CASE

Exploded View

Chaincase

ITEM

DESCRIPTIO

TORQUE SPECIFICATION / NOTES

ITEM

DESCRIPTION

TORQUE SPECIFICATION /

NOTES

Cover bolts

8 ft-lb(11N-m) N

Breather

roll

Chaincase cover

Chaincase

Cover gasket

make sure that the gasket is not pinched

during assembly

Upper seal

Install so that the lip is facing the

chaincase

Cotter pin

bend the ends over the nut flats when

installing

Lower seal

Install so that the lip is facing the

chaincase

Jackshaft nut

50 ft-lb (62.5N-m)

Fill plug

Washer

Drain plug

8 ft-lb (11N-m)

Top sprocket

Install so that the shoulder is facing the

bearing

Lower bearing

Loctite 680 when assembled

Chain tensioner

adjuster

Torque only finger tight during assembly

Lower c-clip

Install so that the chamfered edge is

facing the bearing

Tensioner lock

nut

Chain

Fastener Seal

Thread this onto the adjuster bolt during

assembly

Lower sprocket

Install so that the shoulder is facing the

bearing

Tensioner

Assembly

Washer

Upper c-clip

Install so that the chamfered edge is facing

the bearing

Lower sprocket

retaining bolt

19 ft-lb (26N-m)

Upper bearing

Loctite 680 when assembled

Sight glass

Only remove if replacing

X Y

image depicts 8.373 chaincase, your chaincase may vary slightly

7.8

FINAL DRIVE/BRAKES

Chaincase Removal

Support the rear of the machine and loosen up the track
tension.

Remove RH side panel.

Remove the exhaust system.

Remove the plenum.

Remove drain plug and drain the chaincase fluid.

Once fluid is drained replace drain plug and torque to 8 ft-
lb (11 N-m).

Remove the speedo drive nuts (1) to gain access to the drive
shaft retaining nuts (2).

Remove driveshaft retaining nuts.

Remove the Torx™ screw that holds on the cowling on the
LH side.

10. Remove the Torx™ screws that hold the oil/coolant bottles

to the bracket. This will give you room to remove the
caliper later.

11. Move the RH cowling away from the footrest and remove

the RH storage compartment by prying the top and sides of
the compartment in to clear the foot rest. This will give you
room to access the chaincase retaining bolts.

12. Apply the parking brake.

13. Tip machine over on its LH side.

14. Remove the chaincase cover and clean it.

15. Remove the lower sprocket bolt and washer (X,Y).

16. Remove the cotter pin (D) on the jackshaft.

17. Remove the jam nut (E) and washer (F) on the jackshaft

(upper sprocket).

18. Release the parking brake.

19. Release the tension on the chaincase tensioner (H).

20. Remove the sprockets (G,W) and chain (V) from the

chaincase.

21. Remove the brake caliper bolts.

22. Push the coolant hose enough to remove the caliper out of

the way of the chaincase.

23. Remove the rear suspension.

24. Carefully slide the driveshaft down so that it clears the

chaincase, and remove the driveshaft.

25. Remove the track from the chassis.

26. Remove the chaincase retaining bolts.

27. Slide the chaincase out of the chassis.

28. Inspect the o-ring and seal sleeve on the jackshaft and

replace the o-ring.

29. Service the chaincase.

Chaincase Installation

Install the seal sleeve and o-ring onto jackshaft. The seal
sleeve goes on first then the o-ring.

Install jackshaft installation tool PN 2871296 onto the
jackshaft.This will prevent damage to the seal.

Install assembled chaincase onto the jackshaft in chassis.

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

Insert the track.

Insert the driveshaft and careful guide it through the lower
bearing of the chain case.

Loosely install the lower sprocket on the drive shaft with
the retaining bolt. This will keep the driveshaft from falling
through the other side.

Install the rear suspension.

Tip machine over so that it is upright.

10. Support the rear of the machine with a jack stand.

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

drivers correctly.

12. Remove the jackshaft installation tool from he jackshaft.

13. Install the jackshaft alignment tool on jackshaft and torque

enough so that the jackshaft is aligned with the chaincase
bearing.

14. Torque all chaincase retaining bolts to 28-30 ft-lb (38-41N-

m).

15. Remove the jackshaft alignment tool from jackshaft.

16. Install brake caliper and torque the retaining bolts to 19-21

ft-lb.(26-28 N-m).

= T

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

= T

Chaincase Bolts: 28-30ft-lb (38-41 N-m)

= T

Brake Caliper Bolts: 19-21 ft-lb (26-28 N-m)

7.9

FINAL DRIVE/BRAKES

17. Install the driveshaft by replacing the flangette nuts on the

speedo drive side. torque to 19-21 ft-lb (26-28 N-m).

18. Replace the speedo drive cover.

19. Torque the speedo drive cover nuts to 11 ft-lb (1 5N-m).

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

21. Place the upper sprocket, lower sprocket into the chain, and

install it onto the shafts in the chaincase.

22. Lock the parking brake.

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

24. Install cotter pin and bent the ends around the jackshaft end.

25. Install the lower sprocket retaining bolt. Torque to 19-21

ft-lb.(26-28 N-m).

26. Release the parking brake.

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

28. Lock the adjuster lock nut.

29. Apply silicone at or between the two lower bolts over the

gasket.

30. Install the chaincase cover, and torque the cover bolts to 10

ft-lb (13.5 N-m).

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

level.

32. Check for leaks.

33. Adjust track tension to the specified tension.

34. Install the LH storage compartment into the LH footwell

area.

35. Insert the lower tabs on the cowling in the LH footwell.

36. Replace the Torx™ screw that holds the cowling onto the

steering hoop.

Chaincase Seal & Bearing Replacement

Remove the chaincase as described above.

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

Remove bearing retaining snap rings (L,U).

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.

Clean the chaincase.

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.

Replace the snap rings (L,U).

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.

= T

Speedo Drive Flangette Nuts: 19-21 ft-lb

(26-28N-m)

= T

Speedo Drive Cover Nuts: 11ft-lb (1 5N-m)

= T

Top Sprocket Nut: 50 ft.lb. (6 8N-m)

= T

Bottom Sprocket Bolt: 19-21 ft.lb. (26-28 N-m)

Apply 1/8” bead of silicone to the cover over
the existing gasket

= T

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

7.10

FINAL DRIVE/BRAKES

DRIVE TRAIN

Jackshaft Exploded View

ITEM

DESCRIPTION

TORQUE SPECIFICATION / NOTES

ITEM

DESCRIPTION

TORQUE SPECIFICATION / NOTES

Chaincase

7.92, 8.37, 8.47

Driven Clutch

O-ring

8.37 chaincase - install seal sleeve (C) first,

then o-ring (B) on jackshaft

7.92 chaincase - install seal sleeve (C) first,

then o-ring (B) on jackshaft

Washers

Note the placement

Seal

Flangette Nuts

11 ft-lb (15 N-m)

Brake Disk

Minimum thickness = .193" (4.9mm)

Driveshaft Flangette

Carriage Bolts

Retaining Ring

included on jackshaft

Nylock Nut

11 ft-lb (15 N-m)

Jackshaft

Speedo Pick Up (Speed

Sensor)

Bulkhead area

Speed Sensor Bolt

5 ft-lb (7 N-m)

Bearing

Speedo Pick Up Housing

Flangette

Speedo Pick Up Gasket

Belt

Speedo Wheel Pick Up

and bolt

12-15 ft-lb (8.8-11 N-m)

Spacer

Drive Shaft

7.92 chaincase - install o-ring (B) first then

seal sleeve (C) on driveshaft.

Washers

Chaincase Carriage Bolt

Driven clutch retaining

bolt

17 ft-lb (23 N-m)

Nylock Nut

20 ft-lb (27 N-m)

Content .. 43 44 45 46 ..