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8.18 FINAL DRIVE TRANSMISSION ASSEMBLY Lubricate all parts before assembly with Premium Synthetic 1. Install chain on input and reverse shaft. 2. Add output gear assembly with chain. 3. Add shift fork assembly. 4. Install entire assembly in case half. 5. Apply 3 BondE 1215 Sealant to case halves. 6. Install outer case half and replace brake cable bracket. 7. Install seals, shift arm, brake disc and caliper. Install TRANSMISSION INSTALLATION 1. Tip unit onto right side. 2. Insert track in unit, making sure direction of rotation is 3. Place drive shaft in unit, aligning drive sprockets and track 4. Install lock collar, flangette, bearing, gasket, and flangette 5. Lightly tighten set screws to hold bearing in place. 6. Align flangette holes with tunnel. 7. Replace adaptor key in drive shaft. Install angle drive 8. Install nuts and finger tighten. 9. Tip machine onto its left side. 10. Replace O-rings on input and output shafts. Apply Polaris All Season Grease to drive shaft coupler splines. 11. Reinstall transmission, using care not to damage coolant hoses. Be sure transmission shift linkage is properly 12. Install lower front mounting bolt (3) before coupling to shaft. Once bolt is started into transmission housing, align 13. Install remaining transmission mounting bolts. Reinstall shim washers in original positions and tighten bolts NOTE: Proper transmission/jackshaft alignment is 14. Tip machine onto its right side. 15. Loosen set screws and seat drive shaft in transmission coupler stub shaft. For ease of assembly, make sure track 16. Tighten nuts retaining angle drive housing to tunnel. Torque to specification. 17. Reinstall suspension inside track and align with tunnel mounting holes. 18. Install and hand tighten suspension bolts (1). 19. Install front carrier shaft assembly inside track and mount to tunnel with bolts. Hand tighten bolts. 1 |