6.16
Drive and Brake Systems
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
Gearcase Assembly
Lubricate all parts before assembly with 2W-50 engine oil.
NOTE: Wrap input, low/RVS, and output shaft spline
ends with electrical tape to prevent seal damage
during assembly.
1. Install chain on input and low/RVS shaft.
2. Add output gear assembly with chain.
3. Add shift fork assembly.
4. Install entire assembly in case half making sure the
splines do not damage the case seals.
5. Apply 3 Bond™ 1215 to case mating surfaces.
6. Install outer case. Torque bolts in three steps to 8-10
ft. lbs. (11-14 N-m) using a criss-cross pattern.
7. Install brake disc. Install detent ball, spring, and plug.
Fill with 20 ounces (600cc) Polaris Premium Synthetic
2W-50 Oil.
Gearcase Installation
1. Tip unit onto right side.
2. Insert track in unit, making sure direction of rotation is
correct.
3. Place drive shaft in unit, aligning drive sprockets and
track drive lugs.
4. Install lock collar, flangette, bearing, gasket, and
flangette on drive shaft, positioning bearing flush with
end of drive shaft.
5. Lightly tighten set screws to hold bearing in place.
6. Align flangette holes with tunnel.
7. Replace adapter key in drive shaft. Install angle drive
housing aligning adaptor key with angle drive.
8. Install nuts and finger tighten.
9. Tip machine onto its left side.
10. Replace o-rings on input and output shafts. Apply
Polaris All Season Grease to drive shaft coupler
splines.
11. Reinstall transmission, using care not to damage
coolant hoses. Be sure transmission shift linkage is
properly located.
12. Install lower front mounting bolt (3) before coupling to
shaft. Once bolt is started into transmission housing,
align coupling with drive shaft and jack shaft splines.
Keep transmission flat and lower gradually to prevent
binding of couplers.
13. Install remaining transmission mounting bolts.
Reinstall shim washers in original positions and
tighten bolts securely.
NOTE: Proper transmission/jackshaft alignment is
critical for bearing service life. Use a standard nut and
flat washer for initial installation of transmission, and
install new mounting hardware after jackshaft
alignment is complete.
14. Tip machine onto its right side.
15. Loosen set screws and seat drive shaft in
transmission coupler stub shaft. For ease of
assembly, make sure track has no pressure against
drive shaft.
16. Tighten nuts retaining angle drive housing to tunnel.
Torque to specification.
17. Reinstall suspension inside track and align with tunnel
mounting holes.
18. Install and hand tighten suspension bolts (1).
19. Install front carrier shaft assembly inside track and
mount to tunnel with bolts. Hand tighten bolts.
20. Install rear carrier shaft assembly. Make sure bolts are
not cross threaded and hand tighten.
21. Tip machine back onto floor and tighten all
suspension bolts to specification.
22. If jackshaft was removed from unit, grease coupler
spline with Polaris Premium All Season Grease and
install on transmission.
23. Reattach transmission shift linkage and shift light
connector. Check transmission fluid level and fill if
necessary
24. Install brake caliper. Secure fasteners to 20 ft.lbs.
(27Nm).
25. Install bumper onto footrest bolt and tighten.
To Next Page
Loading...
Need help?
General
