6.10
Drive and Brake Systems
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
Jackshaft Removal
1.
Remove the drive belt.
2.
Remove the driven clutch. Note of the placement of
the washers.
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.
13. Remove the jackshaft assembly from the brake disc
and chassis by tapping on the end of the jackshaft with
a soft face hammer.
14. This will also remove the o-ring and seal.
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 jackshaft assembly through the brake disc.
and install a new o-ring and seal sleeve. Push
jackshaft through chaincase.
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 and bolts. 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 on the drive clutch
end of the jackshaft.
11. Install the driven clutch, spacer, and washers and
torque the retaining bolt to 17 ft-lb (23 N-m).
12. Install the belt.
Driveshaft Removal/Installation
1.
Remove the drain plug and drain the chaincase fluid.
2.
Replace the chaincase drain plug.
3.
Remove the exhaust system.
4.
Remove the chaincase cover.
5.
Loosen the tensioner.
6.
Remove the lower sprocket bolt and washer.
7.
Shut off the fuel valve if equipped.
8.
Remove the speedometer drive housing.
9.
Remove the rear suspension.
10. With the sled over on its left side, and the rear skid
removed, remove the drive shaft.
11. Assemble in reverse order.
= T
Drain Plug: 8 ft-lb (11 N-m)
