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Summary of Contents for Zodiac Polaris 3900 Sport
- Page 1 3900 Sport Tear Down Instructions...
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Page 3: Table Of Contents
TABLE OF CONTENTS DISASSEMBLY BAG SWEEP HOSE REMOVAL ..............4 BOTTOM HOUSING REMOVAL ..............5 WATER MANAGEMENT REMOVAL ............. 6 WHEEL REMOVAL ..................7 GEAR BOX ASSEMBLY ................8 TOP ASSEMBLY .................... 9 DRIVE TRAIN ....................10-14 PRODUCT BREAKDOWN ..................15 COMPONENT PARTS .................... -
Page 4: Bag Sweep Hose Removal
BAG AND SWEEP HOSE REMOVAL Press logo buttons to remove Quick Disconnect Remove bag by twisting collar Remove Sweep hose by twisting nut to release from hose... -
Page 5: Bottom Housing Removal
BOTTOM HOUSING REMOVAL Remove 3 screws from bottom of cleaner Remove Bottom Housing Locate 3 screws labeled “A” and remove. -
Page 6: Water Management Removal
GEAR BOX REMOVAL Remove Water management System and Rear Housing Locate 4 screws labeled “B” and remove Remove Gearbox and single side wheel... -
Page 7: Wheel Removal
GEAR BOX REMOVAL Pry hubcap with flat-blade screw- driver for removal Un-thread screw to remove wheel Pull wheel from gearbox shaft... -
Page 8: Gear Box Assembly
GEAR BOX COMPONENTS Gearbox Assembly Part #39-200 Notes:... -
Page 9: Top Assembly
TOP ASSEMBLY REMOVAL Locate and remove 2 screws in order to remove the Top. Remove Top Top Assembly Part #39-003, includes float. -
Page 10: Drive Train
DRIVE TRAIN REMOVAL Pry hubcap off double-side wheels with flat-blade screw driver Un-thread screw to remove wheel. Remove wheel. - Page 11 DRIVE TRAIN REMOVAL Remove wheel sprocket cover to expose chain Remove chain from rear wheel sprocket Remove Sprocket and note bearing placement...
- Page 12 DRIVE TRAIN REMOVAL Press bearing out with screw- driver and inspect Reinstall bearing with open face into Sprocket Press against closed face of bearing...
- Page 13 DRIVE TRAIN REMOVAL Sprocket Assembles and chain Drivetrain Locate and remove wheel spac- ers from 2 wheel side axles Locate and remove 2 screws at the base of the feed pipe...
- Page 14 DRIVE TRAIN REMOVAL Remove the Vacuum Tube/ Feed pipe assembly. Locate and remove the 2 screws that attach each axle to the frame. Frame assembly with Chain tensioner.
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Page 15: Product Breakdown
COMPONENTS Product Breakdown Notes:... -
Page 16: Component Parts
PART NUMBERS... -
Page 17: Assembly
ASSEMBLY Assemble axle blocks with star washers and screws. Turn frame upside down and install axle blocks to frame. Drop gearbox into place with Brass Brass brass inserts pointing up. Inserts Inserts... -
Page 18: Gear Box
ASSEMBLY Attach gearbox with 4 screws in pockets labeled “B”. Install wheel spacers on double side wheel axle blocks. Attach Vacuum tube/Feed pipe Assembly to frame with 3 screws. -
Page 19: Wheels & Chain
ASSEMBLY Install Wheel Sprockets on double side axle. Wrap chain around front axle sprocket and through tensioner as shown. - Page 20 ASSEMBLY Use the diagram on the Vacuum tube to assist with wrap configuration. Install the 2 sprocket covers. Locate double side wheel noting one bearing in the outer cavity of each wheel.
- Page 21 ASSEMBLY Align wheels into sprockets and attach with locking screw. Locking screw Attach single side wheel with the same locking screw.
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Page 22: Top Assembly
ASSEMBLY Replace top assembly with 2 screws. Inspect o-ring on Water management System. Snap rear housing to Water management System. -
Page 23: Water Management
ASSEMBLY Attach Water management System with 3 screws. Align bottom housing. -
Page 24: Bottom & Sweep Hose
ASSEMBLY Attach bottom housing with 3 screws Snap hub caps on all wheels. Attach sweep hose - install nut first then thread back onto sweep hose. -
Page 25: Bag & Quick Disconnect
ASSEMBLY Note the serial number location under the canopy. Press bag into vacuum tube. Install quick disconnect. - Page 26 Notes:...
- Page 28 3900 SPORT TEARDOWN - 2/12...
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