Snowmobile Polaris Two Stroke (2007 year). Manual - part 46

7.11

FINAL DRIVE/BRAKES

7

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 (27 N-m). 

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 (15 N-m).

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 (23 N-m).

12. Install the belt.

13. Check clutch alignment. See “Clutch Alignment / Offset”

on page 6.14.

ADJUSTMENTS

Chaincase Drive Tension

NOTE: It may be necessary to remove the exhaust
pipe and resonator to access this area.

1.

Elevate the rear of the machine so that the track is off the
floor.

2.

Rotate the driven clutch counterclockwise to move all the
chain slack to the tensioner side.

3.

Lock the parking brake.

4.

Loosen the adjuster bolt jam nut (A).

5.

Finger tighten the adjuster bolt (B).

6.

Back off the adjuster bolt 1/4 turn out (counterclockwise)

7.

Tighten the jam nut while holding the adjuster bolt.

8.

Release the parking brake.

A

B

7.12

FINAL DRIVE/BRAKES

DRIVESHAFT

Driveshaft Removal/Installation

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 (11
N-m).

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.

10. Remove the speedo drive pickup (5).

11. Remove the speedo drive housing (6).

12. Remove the rear skid.

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

remove the drive shaft (7).

14. Assemble in reverse order

1

2

3

4

5

6

7

= T 

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

7.13

FINAL DRIVE/BRAKES

7

WIDETRAK TRANSMISSION

Removal

1.

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

2.

Remove battery.

3.

Turn off fuel valve. Move oil tank for access. 

4.

Remove air intake and coolant recovery bottle from its
mounting.(do not remove entirely).

5.

Remove drive belt.

6.

Remove driven clutch retaining bolt assembly and drive
clutch. Note number of spacers which are behind driven
clutch for installation during reassembly procedures.

7.

Remove muffler springs and muffler from unit.

8.

Loosen brake cable jam nut (1) and remove cable bolt, nut
and spacer (2. Use care not to lose spacer.

9.

Remove cable from transmission.

10. Note location of shift linkage on transmission to assure

proper location during reassembly. Remove cotter pin,
washers, and pin from transmission arm (3).

11. Remove brake light wire connector from sensor.

12. Loosen rear idler wheels and bolts.

13. Loosen jam nuts on adjustment bolts on both sides. Back

out adjustment bolts to allow rear idler assembly to come
forward, relieving track tension.

14. Tighten idler wheel bolts so that spacers on shafts do not

rotate and lose alignment.

15. Remove carrier shaft bolts (4), and front (5) and rear

suspension bolts (6) from both sides.

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

and remove suspension.

17. Remove the bolts, nuts, and flangette supporting jackshaft

bearing. Loosen and slide back lock ring from transmission
end of jackshaft.

18. Remove jackshaft by pulling towards driven clutch side and

lifting upward through bulkhead. It may be necessary to
lightly tap on bearing collar to free coupler of jackshaft
from transmission end. 

19. Inspect bearing. If loose on the shaft the shaft must be

replaced. If bearing is rough when turned, the bearing must
be replaced. The bearing is pressed onto the shaft and will
require a puller for removal.

20. Loosen and remove three carriage bolts and nuts retaining

angle drive housing and flangette.

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

gasket, and bearing from drive shaft and tunnel. 

1

2

3

4

5

6

7.14

FINAL DRIVE/BRAKES

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

22. Tip machine back onto floor.

23. Remove bolt retaining rear of bumper to foot rest.

24. Bend muffler mount out of the way to allow transmission

removal.

25. 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.

26. Lift and maneuver transmission to free drive shaft coupler.

27. Lower drive shaft and remove lower front bolt.

28. Maneuver transmission until it can be removed from the

unit. Use care not to damage coolant lines.

29. With transmission removed, tip unit onto right side. Notice

direction of track rotation for reassembly. The arrow in the
photo at right indicates track bottom, rear of unit.

30. Remove front and rear carrier shafts.

31. Remove suspension by pulling rear of track out of tunnel.

Slide suspension forward to driveshaft. Lift up and out at
the rear.

NOTE:  NOTE: On some models it may be necessary
to unhook rear torque arm springs to allow torque
arm to lower.

32. Inspect transmission, brakes, suspension and track for

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

Inspection

1.

Remove drain plug (1) and drain transmission oil into
suitable container.

2.

Remove snap ring, spacer washer, and brake disc.

NOTE:  Note position of spacer washers behind disc
for proper alignment upon reassembly.

3.

Remove detente spring and ball.

4.

Remove case bolts evenly in a criss-cross pattern.

5.

Tap cases apart with soft faced hammer in the reinforced
areas (2). Tap end of brake shaft to be sure it remains in
case.

6.

Remove shift arm.

7.

Remove shaft and gear assembly (6) from case by tapping
with a soft faced hammer evenly on end of shafts.

1

5

6