Snowmobile Polaris Two Stroke (2007 year). Manual - part 47

7.15

FINAL DRIVE/BRAKES

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

7.16

FINAL DRIVE/BRAKES

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

7.17

FINAL DRIVE/BRAKES

Transmission Assembly

Lubricate all parts before assembly with Premium Synthetic
Chaincase Lubricant.

Install chain on input and reverse shaft.

Add output gear assembly with chain.

Add shift fork assembly.

Install entire assembly in case half.

Apply 3 Bond™ 1215 Sealant to case halves.

Install outer case half and replace brake cable bracket.
Torque bolts in three steps to 8-10 ft. lbs. (11-14 N-m) using
a criss-cross pattern. Remove dowel from tensioner and
install access plug (where applicable).

Install seals, shift arm, brake disc and caliper. Install
detente ball, spring, and spring guide. Fill with 20 ounces
(600cc) Polaris Premium Synthetic 0W-40 Oil.

Transmission 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 adaptor 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.

7.18

FINAL DRIVE/BRAKES

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 brake light

connector. Check transmission fluid level and fill if
necessary

24. Attach brake cable to transmission mounting with bolt, nut

and spacer.

25. Install bumper onto footrest bolt and tighten.

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.

Content .. 45 46 47 48 ..