Polaris 2007 Two Stroke - Chaincase Seal & Bearing Replacement

7.9
FINAL DRIVE/BRAKES
7
17. Install the driveshaft by replacing the flangette nuts on the
speedo drive side. torque to 19-21 ft-lb (26-28 N-m).
18. Replace the speedo drive cover.
19. Torque the speedo drive cover nuts to 11 ft-lb (1 5N-m).
20. Remove the loosely placed lower gear and retaining bolt.
21. Place the upper sprocket, lower sprocket into the chain, and
install it onto the shafts in the chaincase.
22. Lock the parking brake.
23. Replace the top sprocket retaining nut. Torque to 50 ft-lb.
24. Install cotter pin and bent the ends around the jackshaft end.
25. Install the lower sprocket retaining bolt. Torque to 19-21
ft-lb.(26-28 N-m).
26. Release the parking brake.
27. Adjust the chain tensioner by hand and back off 1/4 turn.
28. Lock the adjuster lock nut.
29. Apply silicone at or between the two lower bolts over the
gasket.
30. Install the chaincase cover, and torque the cover bolts to 10
ft-lb (13.5 N-m).
31. Remove the fill cover and fill chaincase to the appropriate
level.
32. Check for leaks.
33. Adjust track tension to the specified tension.
34. Install the LH storage compartment into the LH footwell
area.
35. Insert the lower tabs on the cowling in the LH footwell.
36. Replace the Torx™ screw that holds the cowling onto the
steering hoop.
Chaincase Seal & Bearing Replacement
1. Remove the chaincase as described above.
2. Pry out the old seals (P,Q) from the back side of the
chaincase.
3. Remove bearing retaining snap rings (L,U).
4. Press out the old bearings (M,T) from the back side of the
chain case so that the bearings drop out of the front. If the
bearing pushes out hard, warm the area to expand the
chaincase bore slightly.
NOTE: When removing always push out the bearing
towards the snap ring side of the chaincase.
5. Clean the chaincase.
6. Apply Loctite
® 680 to the outer race of the new bearings
and press them into the chaincase from the snap ring side.
NOTE: Press on the bearing outer race only, or
damage may occur to bearing.
7. Replace the snap rings (L,U).
8. Press in new seals (P,Q) in the back of the chaincase until
the outer edge of the seal is flush with the chaincase
shoulder.
= T
Speedo Drive Flangette Nuts: 19-21 ft-lb
(26-28N-m)
= T
Speedo Drive Cover Nuts: 11ft-lb (1 5N-m)
= T
Top Sprocket Nut: 50 ft.lb. (6 8N-m)
= T
Bottom Sprocket Bolt: 19-21 ft.lb. (26-28 N-m)
Apply 1/8” bead of silicone to the cover over
the existing gasket
= T
Chaincase Cover Bolts: 10 ft.lb. (13.5 N-m)