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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 40

6.16

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Gearcase Assembly

Lubricate all parts before assembly with 2W-50 engine oil.

NOTE: Wrap input, low/RVS, and output shaft spline
ends with electrical tape to prevent seal damage
during assembly.

Install chain on input and low/RVS shaft.

Add output gear assembly with chain.

Add shift fork assembly.

Install entire assembly in case half making sure the
splines do not damage the case seals.

Apply 3 Bond™ 1215 to case mating surfaces.

Install outer case. Torque bolts in three steps to 8-10
ft. lbs. (11-14 N-m) using a criss-cross pattern.

Install brake disc. Install detent ball, spring, and plug.
Fill with 20 ounces (600cc) Polaris Premium Synthetic
2W-50 Oil.

Gearcase Installation

Tip unit onto right side.

Insert track in unit, making sure direction of rotation is
correct.

Place drive shaft in unit, aligning drive sprockets and
track drive lugs.

Install lock collar, flangette, bearing, gasket, and
flangette on drive shaft, positioning bearing flush with
end of drive shaft.

Lightly tighten set screws to hold bearing in place.

Align flangette holes with tunnel.

Replace adapter key in drive shaft. Install angle drive
housing aligning adaptor key with angle drive.

Install nuts and finger tighten.

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 located.

12. Install lower front mounting bolt (3) before coupling to

shaft. Once bolt is started into transmission housing,
align coupling with drive shaft and jack shaft splines.
Keep transmission flat and lower gradually to prevent
binding of couplers.

13. Install remaining transmission mounting bolts.

Reinstall shim washers in original positions and
tighten bolts securely.

NOTE: Proper transmission/jackshaft alignment is
critical for bearing service life. Use a standard nut and
flat washer for initial installation of transmission, and
install new mounting hardware after jackshaft
alignment is complete.

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 has no pressure against
drive shaft.

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.

20. Install rear carrier shaft assembly. Make sure bolts are

not cross threaded and hand tighten.

21. Tip machine back onto floor and tighten all

suspension bolts to specification.

22. If jackshaft was removed from unit, grease coupler

spline with Polaris Premium All Season Grease and
install on transmission.

23. Reattach transmission shift linkage and shift light

connector. Check transmission fluid level and fill if
necessary

24. Install brake caliper. Secure fasteners to 20 ft.lbs.

(27Nm).

25. Install bumper onto footrest bolt and tighten.

6.17

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

26. Reinstall bumper plug.

27. Reinstall and secure muffler.

28. Install battery, air box, oil tank, and coolant recovery

bottle.

29. Loosen rear idler bolts.

30. Reinstall driven clutch and spacers onto jackshaft and

tighten.

31. Reinstall clutch offset washers on jackshaft and install

driven clutch. Using the clutch alignment tool, adjust
driven clutch to achieve proper offset.

32. Widetrak models have no float on driven clutches.

Use shim washers (PN 7555734) to create gap
between shaft and cover washer only.

33. Torque driven clutch retaining bolt to specification.

34. Lift and support rear of unit and align track to

specifications found in the Maintenance section.
Make sure rear idler wheel spacer location is correct
before tightening idler wheels.

6.18

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

HYDRAULIC BRAKE SYSTEM

Overview

The Polaris snowmobile hydraulic brake system consists
of the following components or assemblies: brake lever,
master cylinder, hydraulic hose, brake caliper (slave
cylinder), brake pads, and a brake disc which is secured
to the drive line.

When the hand activated brake lever (A) is applied, it
contacts a piston (B) within the master cylinder. As the
master cylinder piston moves inward it closes a small
opening called a compensating port (C) within the cylinder
and starts to build pressure within the brake system. As
the pressure within the system is increased, the pistons
(D) located in the brake caliper move toward the disc and
applies pressure to the moveable brake pads. As the lever
pressure is increased, the braking effect is increased.

The friction applied to the brake pads will cause the pads
to wear. As the pads wear, the piston within the caliper self-
adjusts and moves further outward.

Brake fluid level is critical to proper system operation. A
low fluid level allows air to enter the system causing the
brakes to feel spongy.

Compensating Port

Located within the master cylinder is a small
compensating port (C) which is opened and closed by the
master cylinder piston assembly. The port is open when
the brake lever is released and the piston is outward. As
the temperature within the hydraulic system changes, this

port compensates for fluid expansion caused by heat, or
contraction caused by cooling. During system service, be
sure this port is open. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for the brake fluid to expand.
Master cylinder reservoirs should be filled to the top of the
fluid level mark on the inside of the reservoir, 1/4" - 5/16"
(.6 -.8 cm) below lip of reservoir opening.

This system also incorporates a diaphragm (E) as part of
the cover gasket and a vent port (on cover) located
between the gasket and the cover. The combination
diaphragm and vent allow for the air above the fluid to
equalize pressure as the fluid expands or contracts. Be
sure the vent is open and allowed to function. If the
reservoir is overfilled or the diaphragm vent is plugged, the
expanding fluid may build pressure in the brake system
and lead to brake failure.

6.19

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Warnings and Cautions

Keep these points in mind when bleeding hydraulic
brakes:

• The master cylinder reservoirs have limited

capacities. It is easy to empty them during the
bleeding procedure. This introduces air into the
system which you are trying to purge. Watch the
reservoir closely and add fluid when necessary to
prevent air from entering the system.

• Apply only light to moderate pressure to the lever

or pedal when bleeding the brake system.
Extreme pressure will cause a surge of fluid
through the small orifices of the brake system
when the bleeder screw is opened and introduce
air into the system by means of cavitation.

• Small amounts of air can become trapped in the

banjo bolt fittings at the master cylinder(s) and
junction points of brake lines. These fittings can be
purged of air by following a standard bleeding
procedure at these fittings (instead of the bleed
screw on caliper) if necessary to speed the
bleeding process. This is usually only needed if
system was completely drained of fluid. Bleed
each line connection, starting with the fitting
closest to the master cylinder, working toward the
caliper, and ending with the bleed screw.

• Always torque banjo bolts and other brake system

fittings to specified torque.

• Change fluid every 2 years, or when fluid is dark or

contamination is suspected.

WARNING

Contaminated brake discs or brake pads greatly reduce

braking performance and increase stopping distance.

Do not attempt to clean contaminated pads. Replace

them. Clean the brake disc with brake cleaner.

This brake system requires ethylene-glycol based fluid

(DOT 4). Do not use or mix different types of fluid such

as silicone-based or petroleum-based.

Do not use brake fluid taken from old, used or unsealed

containers. Never reuse brake fluid.

Keep brake fluid tightly sealed and out of reach of chil-

dren. Brake fluid can accumulate moisture, reducing it's

effectiveness.

A soft, spongy feeling in the brake lever and/or brake

pedal could indicate a hazardous condition in the brake

system. Do not operate the motorcycle until the failure

in the brake system is corrected.

An unsafe condition exists when air is trapped in the hy-

draulic brake system. Air in the brake hydraulic system

acts like a soft spring and absorbs a large percentage

of the pressure developed by the master cylinder. With-

out this pressure, the braking system cannot develop

full braking force to allow for safe, controlled stops. It is

extremely important to bleed the brakes properly after

any brake system work has been performed or when in-

spection reveals spongy brakes.

CAUTION

Pressure bleeding is not recommended. When fluid

surges through the fittings, it is possible to cavitate the

fluid and create air in the system. In addition, the fluid

stored in a pressure bleeder may be contaminated. Al-

ways use fresh DOT 4 brake fluid from a sealed con-

tainer.

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