8.37 Chaincase Removal - Polaris 340 CLASSIC 2006 Manual

FINAL DRIVE
ITEM
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Y
Z

8.37 CHAINCASE REMOVAL

1. Support the rear of the machine and loosen up the track
tension.
2. Remove RH side panel.
3. Remove the exhaust
REMOVAL" on page 3.16.
4. Remove the plenum.
5. Remove drain plug and drain the chaincase fluid.
6. Once fluid is drained replace drain plug and torque to 8 ft-
lb (11Nm).
7. Remove the speedo drive on the drive shaft to gain access
to the drive shaft retaining nuts.
8. Remove driveshaft retaining nuts.
9. 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.
8.8
Table 8-7: Chaincase
DESCRIPTION
Cover bolts
Chaincase cover
Cover gasket
Cotter pin
Jackshaft nut
Washer
Top sprocket
Chain tensioner adjuster
Tensioner lock nut
Fastener Seal
Tensioner Assembly
Upper c-clip
Upper bearing
Breather roll pin
Chaincase
Upper seal
Lower seal
Fill plug
Drain plug
Lower bearing
Lower c-clip
Chain
Lower sprocket
Washer
Lower sprocket retaining bolt
Sight glass
system, see "EXHAUST
TORQUE SPECIFICATION / NOTES
8 ft-lb(11Nm)
make sure that the gasket is not pinched during assembly
bend the ends over the nut flats when installing
50 ft-lb (62.5Nm)
Install so that the shoulder is facing the bearing
Torque only finger tight during assembly
Thread this onto the adjuster bolt during assembly
Install so that the chamfered edge is facing the bearing
Loctite 680 when assembled
Install so that the lip is facing the chaincase
Install so that the lip is facing the chaincase
8 ft-lb (11Nm)
Loctite 680 when assembled
Install so that the chamfered edge is facing the bearing
Install so that the shoulder is facing the bearing
19 ft-lb (26Nm)
Only remove if replacing
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.