Zodiac Polaris 3900 Sport Instructions Manual Download Page 1 | Manualshive

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3900 Sport

Tear Down Instructions

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Summary of Contents for Polaris 3900 Sport

Page 1: ...1 3900 Sport Tear Down Instructions ...

Page 2: ...2 ...

Page 3: ...AL 5 WATER MANAGEMENT REMOVAL 6 WHEEL REMOVAL 7 GEAR BOX ASSEMBLY 8 TOP ASSEMBLY 9 DRIVE TRAIN 10 14 PRODUCT BREAKDOWN 15 COMPONENT PARTS 16 ASSEMBLY AXLE ASSEMBLY 17 GEAR BOX 18 WHEELS CHAIN 19 21 TOP ASSEMBLY 22 WATER MANAGEMENT 23 BOTTOM SWEEP HOSE 24 BAG QUICK DISCONNECT 25 ...

Page 4: ...4 Remove Sweep hose by twisting nut to release from hose Remove bag by twisting collar Press logo buttons to remove Quick Disconnect BAG AND SWEEP HOSE REMOVAL ...

Page 5: ...5 Remove 3 screws from bottom of cleaner Remove Bottom Housing BOTTOM HOUSING REMOVAL Locate 3 screws labeled A and remove ...

Page 6: ...6 Remove Water management System and Rear Housing Locate 4 screws labeled B and remove Remove Gearbox and single side wheel GEAR BOX REMOVAL ...

Page 7: ...7 Pry hubcap with flat blade screw driver for removal Un thread screw to remove wheel Pull wheel from gearbox shaft GEAR BOX REMOVAL ...

Page 8: ...8 Gearbox Assembly Part 39 200 GEAR BOX COMPONENTS Notes ...

Page 9: ...9 Locate and remove 2 screws in order to remove the Top Remove Top Top Assembly Part 39 003 includes float TOP ASSEMBLY REMOVAL ...

Page 10: ...10 Pry hubcap off double side wheels with flat blade screw driver Un thread screw to remove wheel Remove wheel DRIVE TRAIN REMOVAL ...

Page 11: ...11 Remove wheel sprocket cover to expose chain Remove chain from rear wheel sprocket Remove Sprocket and note bearing placement DRIVE TRAIN REMOVAL ...

Page 12: ...12 Press bearing out with screw driver and inspect Reinstall bearing with open face into Sprocket Press against closed face of bearing DRIVE TRAIN REMOVAL ...

Page 13: ...13 Sprocket Assembles and chain Drivetrain Locate and remove wheel spac ers from 2 wheel side axles Locate and remove 2 screws at the base of the feed pipe DRIVE TRAIN REMOVAL ...

Page 14: ...14 Remove the Vacuum Tube Feed pipe assembly Locate and remove the 2 screws that attach each axle to the frame Frame assembly with Chain tensioner DRIVE TRAIN REMOVAL ...

Page 15: ...15 Product Breakdown COMPONENTS Notes ...

Page 16: ...16 PART NUMBERS ...

Page 17: ...17 Assemble axle blocks with star washers and screws Turn frame upside down and install axle blocks to frame Brass Inserts Brass Inserts Drop gearbox into place with brass inserts pointing up ASSEMBLY ...

Page 18: ...18 Attach gearbox with 4 screws in pockets labeled B Install wheel spacers on double side wheel axle blocks Attach Vacuum tube Feed pipe Assembly to frame with 3 screws ASSEMBLY ...

Page 19: ...19 Install Wheel Sprockets on double side axle Wrap chain around front axle sprocket and through tensioner as shown ASSEMBLY ...

Page 20: ...20 Use the diagram on the Vacuum tube to assist with wrap configuration Install the 2 sprocket covers Locate double side wheel noting one bearing in the outer cavity of each wheel ASSEMBLY ...

Page 21: ...21 Align wheels into sprockets and attach with locking screw Attach single side wheel with the same locking screw Locking screw ASSEMBLY ...

Page 22: ...22 Replace top assembly with 2 screws Inspect o ring on Water management System Snap rear housing to Water management System ASSEMBLY ...

Page 23: ...23 Attach Water management System with 3 screws Align bottom housing ASSEMBLY ...

Page 24: ...24 Snap hub caps on all wheels Attach bottom housing with 3 screws Attach sweep hose install nut first then thread back onto sweep hose ASSEMBLY ...

Page 25: ...25 Note the serial number location under the canopy Press bag into vacuum tube Install quick disconnect ASSEMBLY ...

Page 26: ...26 Notes ...

Page 27: ...27 ...

Page 28: ...28 3900 SPORT TEARDOWN 2 12 ...

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