Polaris SUPERSPORT 2006, Manual

Page: 181 / 300

8.9
FINAL DRIVE
8.37 CHAINCASE INSTALLATION
1. Install the seal sleeve and o-ring onto jackshaft. The seal
sleeve goes on first then the o-ring.
2. Install jackshaft installation tool PN 2870974 onto the
jackshaft.This will prevent damage to the seal.
3. Install assembled chaincase onto the jackshaft in chassis.
4. Insert carriage bolts through the back side of the chassis
and install the nylock nuts loosely.
5. Insert the track.
6. Insert the driveshaft and careful guide it through the lower
bearing of the chain case.
7. Loosely install the lower sprocket on the drive shaft with
the retaining bolt. This will keep the driveshaft from
falling through the other side.
8. Install the rear suspension.
9. 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-
41Nm).
15. Remove the jackshaft alignment tool from jackshaft.
16. Install brake caliper and torque the retaining bolts to 19-21
ft-lb.(26-28 Nm).
17. Install the driveshaft by replacing the flangette nuts on the
speedo drive side. torque to 19-21 ft-lb.(26-28 Nm).
18. Replace the speedo drive cover.
19. Torque the speedo drive cover nuts to 11 ft-lb. (15Nm).
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 Nm).
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. Install the chaincase cover, and torque the cover bolts to 10
ft-lb (13.5Nm).
30. Remove the fill cover and fill chaincase to the appropriate
level.
31. Check for leaks.
32. Adjust track tension to the specified tension. See “Track
Tension Data” on page 3.21
33. Install the LH storage compartment into the LH footwell
area.
34. Insert the lower tabs on the cowling in the LH footwell.
35. Replace the torx screw that holds the cowling onto the
steering hoop.
7.92 CHAINCASE REMOVAL
1. Support the rear of the machine and loosen up the track
tension.
2. Remove the exhaust system, see “EXHAUST
REMOVAL” on page 3.16..
3. Remove the air box.
4. Remove drain plug and drain the chaincase fluid.
5. Once fluid is drained replace drain plug and torque to 8 ft-
lb (11Nm).
6. Remove the speedo drive.
7. Apply the parking brake.
8. Shut the fuel off and drain the fuel from the fuel tank.
9. Tip machine over on its LH side.
10. Remove the chaincase cover.
11. Remove the lower sprocket bolt.
12. Remove the cotter pin on the jackshaft.
13. Remove the jam nut and washer on the jackshaft (upper
sprocket).
14. Release the parking brake.
15. Release tension on the chain tensioner.
16. Remove the sprockets and chain from the chaincase.
17. Remove the brake caliper bolts.
18. Lift the caliper out of the way.
19. Carefully slide the driveshaft down so that it clears the
chaincase.
20. Remove the chaincase retaining bolts.
21. Slide the chaincase out of the chassis.
22. Inspect the o-ring and seal sleeve on the jackshaft and
replace the o-ring.
23. Service the chaincase outlined in “CHAINCASE SEAL/
BEARING REPLACEMENT” on page 10.
7.92 CHAINCASE ASSEMBLY
1. Install the o-ring and then the seal sleeve onto the
jackshaft.
2. Install jackshaft installation tool PN 2870974 onto the
jackshaft. This will prevent damage to the seal.
3. Install chaincase onto the jackshaft in chassis.
4. Remove the jackshaft installation tool from the jackshaft.