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Snowmobile Polaris (2006 year). Manual - part 45

8.6

FINAL DRIVE

GEARS AND CHAINS

GEARS

CM = Cut Metal Sprocket PM = Powder Metal Sprocket
CD = Center Distance between top and bottom sprocket.

Table 8-5: Chaincase Gears

PART

NUMBER

DESCRIPTION

CHAINCASE FIT

3221093

17T, 3/4W, 15 SPL, HYVO, PM

7.92
8.37

11.35

3221094

18T, 3/4W, 15 SPL, HYVO, PM

3221095

19T, 3/4W, 15 SPL, HYVO, PM

3221096

20T, 3/4W, 15 SPL, HYVO, PM

3221097

21T, 3/4W, 15 SPL, HYVO, PM

3221098

22T, 3/4W, 15 SPL, HYVO, PM

3221099

23T, 3/4W, 15 SPL, HYVO, PM

3221101

24T, 3/4W, 15 SPL, HYVO, PM

3221102

25T, 3/4W, 15 SPL, HYVO, PM

3222127

26T, 3/4W, 15 SPL, HYVO, PM

3222126

36T, 3/4W, 15 SPL, HYVO, PM

7.92
8.37

11.35

2900010

37T, 3/4W, 15 SPL, HYVO, CM

3222125

37T, 3/4W, 15 SPL, HYVO PM

2900011

38T, 3/4W, 15 SPL, HYVO, CM

3222108

39T, 3/4W, 15 SPL, HYVO, PM

3222099

40T, 3/4W, 15 SPL, HYVO, PM

3222101

41T, 3/4W, 15 SPL, HYVO, PM

2900005

42T, 3/4W, 15 SPL, HYVO, CM

2900016

43T, 3/4W, 15 SPL, HYVO, CM

3221188

43T, 3/4W, 15 SPL, HYVO, PM

1341243

39T, REVERSE, 3/4W, 15 SPL, HYVO, PM

7.92

1341227

40T, REVERSE, 3/4W, 15 SPL, HYVO, PM

1341228

41T, REVERSE, 3/4W, 15 SPL, HYVO, PM

3221164

18T, 7/8W, 15 SPL, HYVO, CM

7.92
8.37

11.35

3221165

19T, 7/8W, 15 SPL, HYVO, CM

3221166

20T, 7/8W, 15 SPL, HYVO, CM

3221167

21T, 7/8W, 15 SPL, HYVO, CM

3221168

22T, 7/8W, 15 SPL, HYVO, CM

3221169

23T, 7/8W, 15 SPL, HYVO, CM

3221170

24T, 7/8W, 15 SPL, HYVO, CM

3221171

25T, 7/8W, 15 SPL, HYVO, CM

8.7

FINAL DRIVE

DRIVE CHAIN

CHAIN CASE

EXPLODED VIEW

Table 8-6: Drive Chains

PART

NUMBER

DESCRIPTION

CHAINCASE FIT

3221114

64P, 3/4W, HYVO CHAIN

7.92
8.37

11.35

3221113

66P, 3/4W, HYVO CHAIN

3221112

68P, 3/4W, HYVO CHAIN

3221115

70P, 3/4W, HYVO CHAIN

3221110

72P, 3/4W, HYVO CHAIN

3221109

74P, 3/4W, HYVO CHAIN

3221108

76P, 3/4W, HYVO CHAIN

3221158

90P, 3/4W, HYVO CHAIN

11.35

3221157

92P, 3/4W, HYVO CHAIN

3221156

94P, 3/4W, HYVO CHAIN

3221161

96P, 3/4W, HYVO CHAIN

3222131

74P, 7/8W, HYVO CHAIN

7.92
8.37

11.35

3222132

76P, 7/8W, HYVO CHAIN

X Y

image depicts 8.373 chaincase, your chaincase may vary slightly

8.8

FINAL DRIVE

8.37 CHAINCASE REMOVAL

Support the rear of the machine and loosen up the track
tension.

Remove RH side panel.

Remove the exhaust system, see “EXHAUST
REMOVAL” on page 3.16.

Remove the plenum.

Remove drain plug and drain the chaincase fluid.

Once fluid is drained replace drain plug and torque to 8 ft-
lb (11Nm).

Remove the speedo drive on the drive shaft to gain access
to the drive shaft retaining nuts.

Remove driveshaft retaining nuts.

Remove the torx screw that holds on the cowling on the
LH side.

10. Remove the torx screws that hold the oil/coolant bottles to

the bracket. This will give you room to remove the caliper
later.

11. Move the LH cowling away from the footrest and remove

the LH storage compartment by prying the top and sides of
the compartment in to clear the foot rest. This will give
you room to access the chaincase retaining bolts.

12. Apply the parking brake.

13. Tip machine over on its LH side.

14. Remove the chaincase cover and clean it.

15. Remove the lower sprocket bolt and washer (X,Y).

16. Remove the cotter pin (D) on the jackshaft.

17. Remove the jam nut (E) and washer (F) on the jackshaft

(upper sprocket).

18. Release the parking brake.

19. Release the tension on the chaincase tensioner (H).

20. Remove the sprockets (G,W) and chain (V) from the

chaincase.

21. Remove the brake caliper bolts.

22. Push the coolant hose enough to remove the caliper out of

the way of the chaincase.

23. Remove the rear suspension.

24. Carefully slide the driveshaft down so that it clears the

chaincase, and remove the driveshaft.

25. Remove the track from the chassis.

26. Remove the chaincase retaining bolts.

27. Slide the chaincase out of the chassis.

28. Inspect the o-ring and seal sleeve on the jackshaft and

replace the o-ring.

29. Service the chaincase outlined in “CHAINCASE SEAL/

BEARING REPLACEMENT” on page 10.

Table 8-7: Chaincase

ITEM

DESCRIPTION

TORQUE SPECIFICATION / NOTES

Cover bolts

8 ft-lb(11Nm)

Chaincase cover

Cover gasket

make sure that the gasket is not pinched during assembly

Cotter pin

bend the ends over the nut flats when installing

Jackshaft nut

50 ft-lb (62.5Nm)

Washer

Top sprocket

Install so that the shoulder is facing the bearing

Chain tensioner adjuster

Torque only finger tight during assembly

Tensioner lock nut

Fastener Seal

Thread this onto the adjuster bolt during assembly

Tensioner Assembly

Upper c-clip

Install so that the chamfered edge is facing the bearing

Upper bearing

Loctite 680 when assembled

Breather roll pin

Chaincase

Upper seal

Install so that the lip is facing the chaincase

Lower seal

Install so that the lip is facing the chaincase

Fill plug

Drain plug

8 ft-lb (11Nm)

Lower bearing

Loctite 680 when assembled

Lower c-clip

Install so that the chamfered edge is facing the bearing

Chain

Lower sprocket

Install so that the shoulder is facing the bearing

Washer

Lower sprocket retaining bolt

19 ft-lb (26Nm)

Sight glass

Only remove if replacing

8.9

FINAL DRIVE

8.37 CHAINCASE INSTALLATION

Install the seal sleeve and o-ring onto jackshaft. The seal
sleeve goes on first then the o-ring.

Install jackshaft installation tool PN 2870974 onto the
jackshaft.This will prevent damage to the seal.

Install assembled chaincase onto the jackshaft in chassis.

Insert carriage bolts through the back side of the chassis
and install the nylock nuts loosely.

Insert the track.

Insert the driveshaft and careful guide it through the lower
bearing of the chain case.

Loosely install the lower sprocket on the drive shaft with
the retaining bolt. This will keep the driveshaft from
falling through the other side.

Install the rear suspension.

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

Support the rear of the machine and loosen up the track
tension.

Remove the exhaust system, see “EXHAUST
REMOVAL” on page 3.16..

Remove the air box.

Remove drain plug and drain the chaincase fluid.

Once fluid is drained replace drain plug and torque to 8 ft-
lb (11Nm).

Remove the speedo drive.

Apply the parking brake.

Shut the fuel off and drain the fuel from the fuel tank.

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

Install the o-ring and then the seal sleeve onto the
jackshaft.

Install jackshaft installation tool PN 2870974 onto the
jackshaft. This will prevent damage to the seal.

Install chaincase onto the jackshaft in chassis.

Remove the jackshaft installation tool from the jackshaft.

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