6.7
Drive and Brake Systems
6
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
Chaincase Removal
1.
Support the rear of the machine and loosen the track
tension.
2.
Remove the exhaust system, and intake airbox.
3.
Remove drain plug and drain the chaincase fluid.
4.
Replace drain plug and torque to 8 ft-lb (11 Nm).
5.
Remove the nuts securing the speedometer flange to
the bulkhead.
6.
Apply the parking brake.
7.
Place a protective mat on the floor, then roll the
snowmobile on to the left-hand side.
8.
Remove the chaincase cover and clean it.
9.
Remove the lower sprocket bolt and washer.
10. Remove the cotter pin, jam nut, and washer from the
jackshaft.
11. Release the parking brake.
12. Release the tension on the chain tensioner.
13. Remove the sprockets and chain from the chaincase.
14. Remove the brake caliper bolts.
15. Remove the rear suspension.
16. Carefully slide the driveshaft down so that it clears the
chaincase, and remove the driveshaft.
17. Remove the track from the chassis.
18. Remove the chaincase retaining bolts.
19. Slide the chaincase out of the chassis.
20. Inspect the o-ring and seal sleeves on the jackshaft
and driveshaft.
21. Remove the two chaincase seals and discard. Inspect
each bearing. Bearings should roll smoothly with no
flat spots. Replace if bearings are loose or are flat-
spotted.
22. When removing bearings, press from the back of the
case to the inside. Always press on the outside
bearing race.
23. When installing bearings, press from the inside of the
case. Apply Loctite 680 to the bearing-to-case mating
surface. Always press on the outside bearing race.
24. When installing new seals, apply a light film of grease
to the inner lip of the seal to aid in driveshaft / jackshaft
installation.
Chaincase Installation
1.
Install new o-rings on the jackshaft and driveshaft.
Install the seal sleeves so that the o-rings fit inside
each sleeve.
2.
Install jackshaft installation tool, PN 2871296, onto
the jackshaft.
3.
Install chaincase onto the jackshaft in chassis.
4.
Loosely install chaincase mounting fasteners.
5.
Install track into the tunnel making sure the arrows
point in the direction of track rotation.
6.
Install the driveshaft.
7.
Loosely install the lower sprocket on the driveshaft.
This will keep the driveshaft from falling through the
other side.
8.
Install the rear suspension, then upright snowmobile.
9.
Support the rear of the machine with a jack stand.
10. Center the track so that it is contacting the drive shaft
drivers correctly.
11. Remove the jackshaft installation tool from the
jackshaft.
12. Install the jackshaft alignment tool on jackshaft, then
torque nut enough so the jackshaft is aligned with the
chaincase bearing.
13. Torque all chaincase retaining bolts.
14. Remove the jackshaft alignment tool from jackshaft.
15. Install brake caliper.
16. Install the driveshaft by replacing the flange nuts on
the speedometer drive side.
17. Remove the loosely placed lower gear and retaining
bolt.
18. Place the upper sprocket, lower sprocket into the
chain, and install it on the shafts in the chaincase.
19. Lock the parking brake.
= T
Chaincase Bolts: 28-30 ft-lb (38-41 N-m)
= T
Brake Caliper Bolts: 19-21 ft-lb (26-28 N-m)
= T
Speedometer Drive Flangette Nuts: 15-17 ft-lb
(21-23 N-m)
