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Snowmobile Polaris (2006 year). Manual - part 47

8.14

FINAL DRIVE

WIDETRAK TRANSMISSION

REMOVAL

Hood can be removed to prevent damage. Mark hood
hinges for ease of alignment when reassembling unit.

Remove battery.

Turn off fuel valve. Move oil tank for access.

Remove air intake and coolant recovery bottle from its
mounting.(do not remove entirely).

Remove drive belt.

Remove driven clutch retaining bolt assembly and drive
clutch. Note number of spacers which are behind driven
clutch for installation during reassembly procedures.

Remove muffler springs and muffler from unit.

Loosen brake cable jam nut (1) and remove cable bolt, nut
and spacer (2. Use care not to lose spacer.

Remove cable from transmission.

10. Note location of shift linkage on transmission to assure

proper location during reassembly. Remove cotter pin,
washers, and pin from transmission arm (3).

11. Remove brake light wire connector from sensor.

12. Loosen rear idler wheels and bolts.

13. Loosen jam nuts on adjustment bolts on both sides. Back

out adjustment bolts to allow rear idler assembly to come
forward, relieving track tension.

14. Tighten idler wheel bolts so that spacers on shafts do not

rotate and lose alignment.

15. Remove front and rear carrier shaft bolts (4), and front and

rear suspension bolts from both sides.

16. Place a protective mat on the floor. Tip unit onto right side

and remove suspension.

17. Remove (2) bolts, nuts, and flangette supporting jackshaft

bearing. Loosen and slide back lock ring from
transmission end of jackshaft.

18. Remove jackshaft by pulling towards driven clutch side

and lifting upward through bulkhead. It may be necessary
to lightly tap on bearing collar to free coupler of jackshaft
from transmission end.

19. Inspect bearing. If loose on the shaft the shaft must be

replaced. If bearing is rough when turned, the bearing
must be replaced. The bearing is pressed onto the shaft and
will require a puller for removal.

20. Loosen and remove three carriage bolts and nuts retaining

angle drive housing and flangette.

8.15

FINAL DRIVE

21. Remove angle drive housing, adaptor key, flangette,

gasket, and bearing from drive shaft and tunnel.

NOTE: It is not necessary to remove speedometer
cable from angle drive. Replace adaptor key any time
drive train assembly is serviced.

22. Tip machine back onto floor.

23. Remove bolt retaining rear of bumper to foot rest.

24. Bend muffler mount out of the way to allow transmission

removal.

25. Remove three transmission retaining bolts. Note all

alignment shim quantities and locations for reassembly.

NOTE: Retaining bolts have to be held in place from
underside while removing nuts. The lower front bolt
cannot be removed at this time. It must be lowered to
the drive sprocket.

26. Lift and maneuver transmission to free drive shaft coupler.

27. Lower drive shaft and remove lower front bolt.

28. Maneuver transmission until it can be removed from the

unit. Use care not to damage coolant lines.

29. With transmission removed, tip unit onto right side. Notice

direction of track rotation for reassembly. The arrow in the
photo at right indicates track bottom, rear of unit.

30. Remove front and rear carrier shafts.

31. Remove suspension by pulling rear of track out of tunnel.

Slide suspension forward to driveshaft. Lift up and out at
the rear.

NOTE: NOTE: On some models it may be necessary
to unhook rear torque arm springs to allow torque
arm to lower.

32. Inspect transmission, brakes, suspension and track for

excessive wear. Check bearings for excessive movement
or rough feeling. Replace if necessary.

INSPECTION

Remove drain plug (1) and drain transmission oil into
suitable container.

Remove snap ring, spacer washer, and brake disc.

NOTE: Note position of spacer washers behind disc
for proper alignment upon reassembly.

Remove detente spring and ball.

Remove case bolts evenly in a criss-cross pattern.

Tap cases apart with soft faced hammer in the reinforced
areas (2). Tap end of brake shaft to be sure it remains in
case.

Remove shift arm.

Remove shaft and gear assembly (6) from case by tapping
with a soft faced hammer evenly on end of shafts.

8.16

FINAL DRIVE

Remove output gear assembly (7) and chain (8). Mark
chain direction for reference during reassembly. Inspect
gear teeth for damage. Inspect chain for worn, cracked, or
broken link plates.

Remove shift fork shaft (9) from gear cluster. Inspect
surface of fork for wear or bending.

10. Remove chain from input and reverse shaft. Inspect gear

teeth for damage. Inspect chain for worn, cracked, or
broken link plates.

11. Inspect dog gears and slots in mating gears closely.

Rounded edges will cause gears to disengage under load.
Replace both dog gear and mating gear if edge of dog and/
or slot is rounded. Inspect gears for chipped, cracked, or
broken teeth.

12. Gear, shaft, and chain cluster assembly shown.

13. Low gear output power flow...

14. High gear output power flow...

GEAR ASSEMBLY

LOW GEAR

HIGH GEAR

8.17

FINAL DRIVE

15. Reverse output power flow...

LOW/REVERSE SHAFT DISASSEMBLY

Press bearing from end of shaft using a bearing separator.

Remove snap ring and spacer washer.

Remove low reverse shaft (1), low gear (2), needle bearing
(3), thrust washer (4), low/reverse dog gear (5).

Remove Snap ring (6), thrust washer (7) (.125”), reverse
idler (8), and thrust washer (9) (.065”).

Closely inspect drive dogs. Replace gear and mating gear
if rounded, chipped or broken.

Inspect needle bearings for wear or cracks on cage. Shiny
spots on cage indicate wear and the bearing should be
replaced. Inspect shaft and thrust washers for galling or
wear. Always replace snap rings if removed.

SHIFT FORK DISASSEMBLY

Remove the detente cam, spring and shaft.

Check condition of key way and key. Inspect indicator,
spring legs and detente areas for wear. Replace parts as
required.

NOTE: The spring must be pre-loaded upon
installation. Refer to photo and illustration below.

REVERSE

7 6

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