Polaris SUPERSPORT 2006, Manual

Page: 182 / 300

8.10
FINAL DRIVE
5. Insert carriage bolts through the back side of the chassis
and install the nylock nuts loosely.
6. Install the jackshaft alignment tool on jackshaft and torque
enough so that the jackshaft is aligned with the chaincase
bearing.
7. Torque all chaincase retaining bolts to 20 ft-lb (27Nm).
8. Install the track in the chassis.
9. Install the o-ring and then the seal sleeve onto the
driveshaft.
10. Carefully guide the drive shaft through the lower bearing
of the chain case.
11. Loosely install the lower sprocket on the drive shaft with
the retaining bolt. This will keep the driveshaft from
falling through the other side.
12. Install the rear suspension.
13. Tip machine over so that it is upright.
14. Turn the fuel valve on.
15. Support the rear of the machine.
16. Center the track so that it is contacting the drive shaft
drivers correctly.
17. Install brake caliper and torque the retaining bolts to 30 ft-
lb.(41 Nm).
18. Remove the loosely placed lower gear and retaining bolt.
19. Place the upper sprocket, lower sprocket into the chain,
and install it onto the shafts in the chaincase.
20. Lock the parking brake.
21. Replace the top sprocket retaining nut. Torque to 50 ft-lb.
22. Install cotter pin and bent the ends around the jackshaft
end.
23. Install the lower sprocket retaining bolt. Torque to 19 ft-lb.
(26Nm).
24. Release the parking brake.
25. Adjust the chain tensioner by hand and back of 1/4 turn.
26. Lock the adjuster lock nut.
27. Install the chaincase cover, and torque the cover bolts to 8
ft-lb (11Nm).
28. Remove the fill cover and fill chaincase to the appropriate
level.
29. Check for leaks.
30. Adjust track tension to the specified tension. See “Track
Tension Data” on page 3.21
CHAINCASE SEAL/BEARING
REPLACEMENT
1. Remove the chaincase as described above.
2. Pry out the old seals (P,Q) from the back side of the
chaincase.
3. Remove bearing retaining snap rings (L,U).
4. 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.
5. Clean the chaincase.
6. 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.
7. Replace the snap rings (L,U).
8. 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.