Removal; Inspection; Gear Ratio Modification; Installation - BOMBARDIER ski-doo Tundra Scandic 2004 Series Shop Manual

REMOVAL

To remove chaincase proceed as follows.
Remove tuned pipe and muffler.
WARNING
Never remove exhaust components when en-
gine is hot.
Remove hair pin no. 8. Release drive chain ten-
sion by unscrewing tensioner adjustment screw.
Drain oil by removing chaincase cover no. 2.
Apply brakes.
Remove cotter pin no. 3, nut no. 4, washer no. 26
retaining upper sprocket no. 5 and screw no. 15
retaining lower sprocket no. 16. Pull sprockets
and drive chain simultaneously. Remove shims
nos. 6 and 17.
NOTE: Should countershaft removal be required,
refer to BRAKE then look for BRAKE DISC.
Remove 5 nuts no. 14. Three nuts are behind the
lower sprocket.
Unfold locking tab no. 23, then remove caliper re-
taining screws no. 22.
Release track tension, use drive axle holder (P/N
529 007 200).
TYPICAL
1. Drive axle
2. Suspension cross shaft
Pry out drive axle oil seal no. 20 from chaincase.
Pull chaincase from drive axle and countershaft.
Using 2 prybars inserted between chaincase no. 7
and frame, pry complete assembly from vehicle.
MMR2004-127_05_07A.FM
Section 05 TRANSMISSION
Subsection 07 (CHAINCASE)

INSPECTION

Visually inspect the chain for cracked, damaged or
missing links. Check for worn or defective bear-
ings, sprockets and chain tensioner components.
WARNING
If chain deflection is greater than 38 mm (1.5 in)
(without chain tensioner), replace chain and
check condition of sprockets.

GEAR RATIO MODIFICATION

For particular applications, the number of teeth of
the sprockets can be increased or decreased on
lower and upper sprockets.
Refer to TECHNICAL DATA for gear ratios.
CAUTION: Gear ratio modifications should
only be performed by experienced mechanics
since they can greatly affect vehicle perfor-
mance.
NOTE: For high altitude regions, a Service Bulletin
will give information about calibration according to
altitude.

INSTALLATION

Reverse removal procedure and pay attention to
the following. Replace oil seals, gaskets and O-rings.
Sealed side of bearing no. 27 must face chaincase
cover.
11, Oil Seal
Clean chaincase bore with cleaning solvent then
apply Loctite 609 to oil seal mounting surface (out-
side).
Using pusher (P/N 529 035 584), press the oil seal
into chaincase hub. Oil seal must fit flush with the
chaincase edge.
NOTE: Should installation procedure for counter-
shaft be required, refer to BRAKE then look for
BRAKE DISC AND COUNTERSHAFT BEARING
ADJUSTMENT.
5,16, Sprockets
Position the sprockets with the writing facing the
chaincase cover.
05-07-5