7.8
FINAL DRIVE/BRAKES
Chaincase Removal
1. Support the rear of the machine and loosen up the track
tension.
2. Remove RH side panel.
3. Remove the exhaust system.
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 (11 N-m).
7. Remove the speedo drive nuts (1) to gain access to the drive
shaft retaining nuts (2).
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 RH cowling away from the footrest and remove
the RH 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.
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.
Chaincase Installation
1. Install the seal sleeve and o-ring onto jackshaft. The seal
sleeve goes on first then the o-ring.
2. Install jackshaft installation tool PN 2871296 onto the
jackshaft.This will prevent damage to the seal.
3. Install assembled chaincase onto the jackshaft in chassis.
4. Insert carriage bolts through the back side of the chassis and
install the nylock nuts loosely.
5. Insert the track.
6. Insert the driveshaft and careful guide it through the lower
bearing of the chain case.
7. Loosely install the lower sprocket on the drive shaft with
the retaining bolt. This will keep the driveshaft from falling
through the other side.
8. Install the rear suspension.
9. Tip machine over so that it is upright.
10. Support the rear of the machine with a jack stand.
11. Center the track so that it is contacting the drive shaft
drivers correctly.
12. Remove the jackshaft installation tool from he jackshaft.
13. Install the jackshaft alignment tool on jackshaft and torque
enough so that the jackshaft is aligned with the chaincase
bearing.
14. Torque all chaincase retaining bolts to 28-30 ft-lb (38-41N-
m).
15. Remove the jackshaft alignment tool from jackshaft.
16. Install brake caliper and torque the retaining bolts to 19-21
ft-lb.(26-28 N-m).
= T
Drain Plug: 8 ft.lb (11 N-m)
1
2
= T
Chaincase Bolts: 28-30ft-lb (38-41 N-m)
= T
Brake Caliper Bolts: 19-21 ft-lb (26-28 N-m)
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