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1999 Polaris Service Manual

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1. 8 Loosen brake cable jam nut A and remove cable bolt nut and spacer B Use care not to loose spacer 9 Remove cable from transmission 10 Note location of shift linkage on transmission A to assure proper location during reassembly Remove cotter pin washers and pin from transmission arm 11 Remove brake light wire connector from sensor 10 98 8 52 Polaris Industries Inc 12 13 14 15 16 17 18 19 20 BRAKES FINAL DRIVE Transmission Suspension and Track Removal WideTrak LX Loosen rear idler wheels and bolts Loosen jam nuts on adjustment bolts on both sides Back out adjustment bolts to allow rear idler assembly to come forward relieving track tension Tighten idler wheel bolts so that spacers on shafts do not rotate and lose alignment Remove front and rear carrier shaft bolts A and front and rear suspension bolts from both sides B Place a protective mat on the floor Tip unit onto right side and remove suspension Using T handle Allen wrench loosen set screws on lock collar Remove 2 bolts nuts and flangettes supporting jackshaft bearing Loosen and slide back lock ring from transmission end of jackshaft Remove jackshaft by pulling towards driven clutch side and lifting upward through bulkhead It may be necessary to lightly tap on bearing collar to free coupler of jackshaft from transmission end Inspect bearing If loose on the shaft the sha
2. Polaris Industries Inc 8 61 10 98 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX 10 Remove shift fork shaft from gear cluster Inspect surface of fork for wear or bending 11 Remove chain from input and reverse shaft Inspect gear teeth for damage Inspect chain for worn cracked or broken link plates 12 Inspect dog gears and slots in mating gears closely Rounded edges will cause gears to disengage under load Replace both dog gear and mating gear if edge of dog and or slot is rounded Inspect gears for chipped cracked or broken teeth 10 98 8 62 Polaris Industries Inc Gear shaft and chain cluster assembly shown Low gear output power flow High gear output power flow Reverse output power flow Polaris Industries Inc 8 63 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX 10 98 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX Low Reverse Shaft Disassembly 13 Press bearing from end of shaft using a bearing separator 14 Remove snap ring and spacer washer 10 98 8 64 Polaris Industries Inc 15 Remove low reverse shaft low gear needle bearing thrust washer low reverse dog gear snap ring thrust washer 050 reverse idler needle bearing and thrust washer 065 16 Closely inspect drive dogs Replace gear and mating gear if rounded chipped or broken 17 Inspect needle bearings for wear or cracks on cag
3. Wear Strip Kits 2871911 1 piece tunne Sport 1 05 2871540 1 piece tunnel SKS 625 2871541 1 piece tunnel SKS 75 2871544 121 75 2871542 2 piece tunnel SKS 625 2871543 2 piece tunnel SKS 75 2871545 121 625 2871689 75 Indy 340 Patent Pending Carbide 60 Point Production set up of wear strips will be located over the windows of the track An optional position is available for using hooker plates Only the outer end holes are punched in the tunnel The wear strip will serve as the template for drilling the remaining holes Polaris Industries Inc 8 75 10 98 BRAKES FINAL DRIVE Traction Stud Installation 1 Markthe stud pattern on the track 2 Drill stud holes with a 1 4 or 7mm hollow core drill bit Make sure the drill is sharp for a clean hole 3 Spin the non cutting portion of the drill shank in the hole at high speed to melt the cords together or melt them with a 1 4 9 32 heated probe This will prolong track life T nut Studs 1 Pusha T nut tool through the hole from the outside of the track 2 With the barrel end of the T nut toward the track spin a T nut onto the tool Pull the T nut into the track until the head is flush with the track Remove the tool and put a drop of Loctite 262 or 271 on the nut threads and stud threads Secure the T nut slide a support washer onto the stud and screw the stud into the T nut Torque to 80 100 in lbs and let dry for 24 hours at room temperature Check
4. splines Polaris All Season Grease PN 2871423 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 Polaris Industries Inc 8 55 10 98 BRAKES FINAL DRIVE Transmission Suspension and Track Assembly WideTrak LX Assembly Cont 15 16 18 19 20 21 22 Using T handle Allen wrench torque set screws to 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 Tighten nuts retaining angle drive housing to tunnel Torque to specification Angle Drive Housing Retaining Nut Torque 15 17 ft Ibs 2 07 2 35kg m specification Set Screw Torque 80 in Ibs 92 kg m Reins
5. 1 53 D 80 o 1 P Sport Touring 133 5x15 82 2871541 1 53 o s p qwe P Trail Touring 133 5x15 82 2871541 313 53 N 8 Nn e Classic Touring 1335x15 82 2871541 1 53 jR cCoMP so R comP 16 s coMP _ XLT Touring 1335x15 82 2871541 1 so R COMP 106 R COMP 132 S COMP 700SKS 136x15 125 NA NA NA R COMP NA R COMP NA S COMP TraiRMK 136x15 125 NA NA NA R COMP NA R COMP NA S COMP S00RMK 1335x15 125 NA NA NA jR COMP NA R COMP NA S COMP 600 RMKOpt2 136x15 20 NA NA NA R COMP NA R COMP MNA _ S COMP 700RMK Opt2 136x15 20 NA NA na R COMP NA R COMP NA S com Transport 141x15 1125 NA NA NA Dorm NA NA NA NA 10 ae WideTrak LX 156 x 20 Ss HE de 2 IO ADS A ee ER EZ Steer skag lee ERA VER ESAS CGE VAIS SS A E DECEM CR PO IE rei 10 98 8 74 Polaris Industries Inc BRAKES FINAL DRIVE Traction Polaris Push Through Stud and Skag Recommendations B 7 16 x 3 120 2870693 Stud Kits C 7 16x 3 120 EZ 2870997 See Accessory Order Forms for Stud Kits D 7 16 x 4 60 2871288 J 7 16 x 6 60 EZ 2871416 N 7 16 x 4 60 EZ 2871603 P 1 2 x 6 60 2871601 1 2 x 8 60 2871602 Polaris Composite Ski R 7 16 x 4 60 2871688 S 1 2 x 6 60 2871687
6. Assembly Screw Lever and Pivot Pin Kit Screw Body Reservoir Clamp Kit 10 Brakelight Switch 11 Cartridge Kit 12 LH Contro Asm 13 Pivot Pin Kit 14 Parking Lever and Spring Kit CONDO RWN gt Park Brake Lever Lock A WARNING Release park brake lock before driving or brake sys tem failure or fire may result Apply brake lever to re lease Hayes Master Cylinder Removal 1 Position clean shop cloths to catch spilled fluid CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 2 Remove the handlebar protector pad from the outlet end of the handlebar master cylinder to access the brake fluid line connector Remove handlebar cover strips Remove two screws Remove holding clip in front of cover eRemove handlebar pad 3 Loosen the connector approximately 1 4 to 1 2 turn 4 Loosen and remove the four switch pack and handlebar master cylinder mounting screws Put screws aside for later installation 10 98 8 16 Polaris Industries Inc BRAKES FINAL DRIVE Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly 5 Remove master cylinder from switch pack and handlebar Remove switch pack wires from the master cylinder housing with extreme care and note where they are routed for later installation 6 Remove master cylinder cover screws and cover Pour out the fluid in the resrevoir int
7. Control Torque 24 28 in Ib 27 32 kg m Polaris Industries Inc 8 19 BRAKES FINAL DRIVE Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly 12 Tighten brake line connector at outlet to 1 ft Ib plus two turns Brake Line Torque dft Ib 14 kg m plus 2 turns 13 Fill reservoir with clean D O T 3 brake fluid Polaris DOT 3 Brake Fluid PN 2870990 14 Bleed brakes as outlined on pages 8 14 and 8 15 Check entire systemfor leaks and fill reservoir to fluid level line 15 Install master cylinder reservoir cover and gasket Torque screws to 15 18 in Ibs 17 20 kg m Cover Screw Torque 15 18 in Ib 17 20 kg m 10 98 8 20 Polaris Industries Inc BRAKES FINAL DRIVE Hayes Master Cylinder Lever and or Pivot Pin Replacement Lever and or Pivot Pin Removal 1 For ease of service remove master cylinder assembly as outlined on pages 8 17 and 8 18 2 Squeeze the lever handle and actuate the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin up through the hole 4 Remove the pivot pin and the lever Polaris Industries Inc 8 21 10 98 BRAKES FINAL DRIVE Hayes Master Cylinder Lever and or Pivot Pin Replacement Lever and or Pivot Pin Installatio
8. Removal 1 Remove bearing retaining snap rings 2 Pry out old seal from back side of chaincase 3 Press out old bearing from side shown If bearing appears tight use heat to expand chaincase bore Always press bearing toward snap ring side of chaincase when removing Inspect chaincase for any damage and replace if required Jackshaft Removal 1 Remove O Ring seal sleeve and brake disc by tapping on jackshaft end with a soft face hammer as shown 2 Remove jackshaft 3 For set screw and Skwez loc bearings inspect drive shaft and jackshaft in bearing contact area If diameter is 001 025 mm less than non contact area shafts should be replaced di Jackshaft and Driveshaft Service Limit NOTE On models with pressed bearing on jackshaft shaft will have to be brought through bulkhead slot in order to re move from unit 10 98 8 42 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Drive System Driveshaft Removal 1 Tip machine back on left side 2 Remove driveshaft by pushing through bearing hole on the bulkhead then pulling driveshaft toward you 3 After drive shaft has been removed inspect condition of drive sprockets and replace if required NOTE On models with pressed bearings on drive shaft If bearings are loose internally or rough they should be replaced e f bearings are loose on the shaft the shaft must be replaced Polaris Industries Inc 8 43 10 98 BR
9. at transmission coupler and torque to specification Lock Ring Torque 80 in Ibs 92 kg m Polaris Industries Inc 8 57 10 98 BRAKES FINAL DRIVE Transmission Suspension and Track Assembly WideTrak LX Assembly Cont 29 30 31 32 33 34 35 36 37 38 Reattach transmission shift linkage and brake light connector Check transmission fluid level and fill if necessary Polaris Synthetic Gearcase Lube PN 2871477 Gallon PN 2871478 12 oz Attach brake cable to transmission mounting with bolt nut and spacer install bumper onto footrest bolt and tighten Reinstall bumper plug Reinstall and secure muffler Install battery air box oil tank and coolant recovery bottle Loosen rear idler bolts Reinstall driven clutch and spacers onto jackshaft and tighten Reinstall clutch offset washers on jackshaft and install driven clutch Using the clutch alignment tool adjust driven clutch to achieve proper offset P85 Electric Start Offset 1 with straightedge _ WideTrak models have no float on driven clutches Use shim washers PN 7555734 to create gap between shaft and cover washer only 10 98 8 58 Polaris Industries Inc BRAKES FINAL DRIVE Transmission Suspension and Track Assembly WideTrak Models 39 Torque driven clutch retaining bolt to specification Driven Clutch Retaining Bolt Torque 12 ft Ibs 1 66 kg m 40 Lift
10. for loose studs after each event Push Through Studs 1 Push stud through track hole from inside track Hand tighten domed support plate and Nyloc nut on the exposed stud 2 Tighten with a socket on the nut and a 5 32 Allen wrench on the stud head Tighten nut until the domed washer bottoms out on the stud shoulder If tightened beyond this point the threads will be stripped 3 Inspect for loose nuts after each event ome Refer to the diagrams below for stud length recommendations Penetration Stud Length A Stud Height B Washer Thickness C Track Lug Height A B C Penetration Maximum Maximum Penetration Stud Length Standard Low Profile Track Se AP r Load AL U Deep Lug Track 3 8 875 E oae NITTI C Steel Cleated Track Backer Plates 3 8 I 700 Steel 195 gt Aluminum 220 Stud Mate 148 Td Hooker Alum Washer 025 Shim 055 10 98 8 76 Polaris industries Inc
11. from caliper using a caliper piston pliers commercially available or by covering the piston with a shop cloth and applying compressed air to the hydraulic inlet port Use only enough air to remove piston Too much pressure may damage piston or bore 8 Using a small wooden or plastic stick work piston seal out from its groove in the piston bore To avoid scratching bore or burring edge of seal groove do not use a metal tool such as a screwdriver 9 Discard old seal Polaris Industries Inc 8 27 10 98 BRAKES FINAL DRIVE Type H4 Brake System Type H4 Cleaning and Inspection Check all parts for wear or damage and replace as required Always replace caliper piston seal and dust seal where applicable 1 Cleanall parts with denatured alcohol and wipe dry with a clean lint free cloth 2 Using compressed air blow out the drilled passages and piston bore Be sure piston seal groove is thoroughly clean and free from corrosion or brake fluid build up 3 Inspect piston bore for scoring pitting or corrosion A corroded or deeply scored casting should be replaced Light scores and stains may be removed by polishing with a crocus cloth only Use finger pressure and rotate the crocus cloth in the cylinder bore Do not slide the cloth in and out of the bore under pressure Do not use any other kind of abrasive cloth 4 Check piston to see if it is pitted scored or worn If so discard and replace the piston Do not attempt to p
12. installing drive sprockets all dimensions are indicated as the shaft is being pressed onto the sprockets Mark the shaft with a Dykem and a machinist scribe or a fine line permanent marker for proper sprocket placement Allow mark to thoroughly dry prior to assembly Verify proper placement using a straight edge and square on sprocket hub and shaft as shown On WideTraks measure from coupler as shown Polaris Industries Inc 8 7 10 98 BRAKES FINAL DRIVE Track Specifications 1999 Track Length x Width Lug Height Indy 340 340 Deluxe 121 x 15 Block Indy 340 Touring 133 5 x 15 Lightning Indy Sport Touring 133 5 x 15 Lightning 8 4 6 4 6 Indy TranSport 141 x 15 1 125 Indy XCF 121 x 15 New Yokohama Indy Super Sport 121 x 15 Lightning Indy 700 XCR 121 x 15 91 Indy 800 XCR 121 x 15 12 3 2 3 8 3 6 4 6 3 6 4 8 4 6 3 6 3 43 6 3 43 10 98 8 8 Polaris Industries Inc BRAKES FINAL DRIVE Hydraulic Brake System Operation The Polaris snowmobile nydraulic brake system consists of the following components or assemblies brake lever master cylinder hydraulic hose brake caliper slave cylinder brake pads and a brake disc which is secured to the drive line When the hand activated brake lever A is applied it contacts a piston B within the master cylinder As the master cylinder piston moves inward it closes a small opening called a c
13. lease Type 3 Master Cylinder Removal 1 Position clean shop cloths to catch spilled fluid and remove brake hose Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 2 Remove brake clamp attaching bolts Item 17 3 Remove park brake lever Item 9 and brake master cylinder lever Item 6 noting position of bushing spring etc for proper reassembly 4 Using the master cylinder service tool position push rod through small hole in spring seat washer Item 12 as shown Remove piston assembly spring and washer Master Cylinder Service Tool K PN 2870962 10 98 8 10 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Master Cylinder Inspection and Assembly Inspection NOTE Due to the critical nature of these parts and pro cedures be sure you have thoroughly read and under stand Hydraulic Brake Operation page 8 9 1 Thoroughly clean all brake parts with isopropyl alcohol inspect piston for wear scratches or corrosion Check master cylinder bore for Scratches score marks or corrosion and replace any worn or damaged parts Assembly 1 Always replace O Ring seal U pack seal and cover gasket diaphragm upon reassembly Use only genuine Polaris service parts Apply clean DOT 3 brake fluid on piston piston seals and cylinder bore Install seals onto piston positioning U pack seal lip A towards spring Snap spring into place o
14. operating position Check for proper fluid level in master cylinder and replace cover Torque to specification Be sure to bleed coolant system as outlined in Engine section Bleed brake system as outlined on pages 8 14 8 15 Field test at low speeds before putting into regular service Polaris Industries Inc 8 31 10 98 BRAKES FINAL DRIVE Type H5LC Brake System Type HSLC Caliper Disassembly Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line oo OY Qv d co TO t Bleeder Screw 10 11 Caliper Liquid Cooled Rope Guide 12 Water Cooler Manifold 13 Screws Cooler Manifold WARNING The rider s safety depends on cor rect installation Follow proce dures carefully Refer to the exploded view above while performing the following steps 1 Remove bracket bolts Disconnect brake line Drain brake fluid into appropriate container and dispose of properly Disconnect and plug coolant lines catching and disposing of antifreeze properly Disassemble on a clean bench Open bleed screw Drain brake fluid into appropriate container and dispose of properly 2 3 4 5 Protect eyes from brake fluid 6 Slide brake assembly out of bracket and remove old pads and clips 7 Place caliper on bench with piston down 8 Remove piston from caliper using a caliper piston pliers commercially available or by covering t
15. place using clips Slide brake assembly into bracket until both clips snap into grooves in bracket Separate pads for installation over disc Place brake assembly over disc and push bracket into chaincase Replace 3 8 bolts rope guide and washers Torque to specification Perform brake bleeding procedure as outlined after System Rebuild page 8 14 8 15 Polaris Industries Inc 8 29 10 98 BRAKES FINAL DRIVE Type H5LC Brake System The Type H5LC system like the Type H4 is a top mounted hydraulic brake system The difference between the two systems is the the H5LC is equipped with a brake cooler Type H5LC Friction Pad Replacement Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw 10 Caliper Liquid Cooled 11 Rope Guide 12 Water Cooler Manifold 13 Screws Cooler Manifold WARNING 0 co SE Orari Doce The rider s safety depends on cor rect installation Follow proce dures carefully Protect eyes from brake fluid 1 Clean any dirt from mount bracket and bolts 2 With a 9 16 socket remove two 3 8 hex bolts and washers from bracket Remove rope guide NOTE Do not disconnect brake line 3 Hemove hose clamp from engine side of cooler Twist and remove hose from cooler catching and disposing of antifreeze properly 4 Use a drop cloth to protect surfaces from brake fluid spillage R
16. positioning of the actuating arm to the caliper helix shaft Improper positioning will result in minima resistance and ineffective brakes 4 With brake lever bottomed on handlebar as if brakes were applied and helix shaft D bottomed in caliper install actuating arm jam nut locking tab jam nut and adjuster bolt Release brake arm slightly to index lever for installation on helix shaft 5 Inserta 015 04 cm feeler gauge between brake disc and moveable brake pad Release brake lever Install return spring Item 13 and finger tighten bolt Item 24 Set adjuster bolt jam nut bend locking tab and remove feeler gauge Friction Pad Air Gap 015 38 mm 6 Field test machine for proper braking action before putting into service If braking action is soft re index helix shaft and repeat steps 3 6 Polaris Industries Inc 8 37 10 98 BRAKES FINAL DRIVE Type WT Mechanical Brake System The Type WT system is the mechanical brake system used only on Indy WideTrak models t0 go ox ors cout Transmission Brake Cable and Jam Nuts Bracket Brake Cable Washer Washer Spring Lock Bolt Top Mount Bracket Brake Top Mounting Bushing Nut Bi Lock Adjuster Bolt Caliper Stationary Cast Pad Brake Puck Moveable Brake Spring Brake Return Nut Bushing Brake Arm Bolt Cable Swivel Clevis LT Bolt Caliper Brake Disc Seal Caliper Moveable Puck Type WT Brake Disassembly Whenever i
17. rope guide NOTE Do not disconnect brake line 3 Lift bracket and brake assembly off vehicle Remove all dirt from caliper assembly using brake cleaner and clean shop cloths 4 Use a drop cloth to protect surfaces from brake fluid spillage Remove reservoir cover from master cylinder assembly Using a large hardwood dowel or a C clamp vise grip on the center of the old pads apply pressure toward the caliper piston Compress piston back into caliper assembly Apply pressure slowly to prevent excessive spillage from master cylinder assembly NOTE Pushing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow Remove excess fluid and discard Piston must not be forced back into the caliper at an angle or bore damage may occur 5 Slide caliper and brake pads out of bracket Discard old pads and clips NOTE Pad and holders must be replaced as a set Polaris Industries Inc 8 25 10 98 BRAKES FINAL DRIVE Type H4 Brake System Type H4 Friction Pad Replacement Cont 6 e 10 11 12 13 14 Place new pads with friction material facing each other into housing Hold in place using clips See illustration on page 8 25 Slide brake assembly into bracket until both clips snap into grooves in bracket Clean brake mount on top of chaincase Separate pads for installation over disc If brake assembly does not slide easily over the disc with loose pads the piston is
18. to functionality Carbide is the most durable and lasts much longer than steel Studs should be installed no closer than 1 from the edges of the track Avoid the center of the track because there is poor support in this area The track s center belt controls acceleration The two smaller outside track belts contribute to acceleration but also increase the amount of ski pressure required for turning The chart on page 8 74 is a guideline for the quantity of studs to install e Be sure to check allowable clearance between the track and tunnel or heat exchangers factoring in suspension travel Do not place studs under the tunnel protector heat exchanger strips directly above slide rails on un derside of tunnel Tunnel protectors are vital components and must not be subjected to stud dam age e V shaped stud patterns with the least repetition work best Studs should cover as many different lines in the ice as possible e Studs closest to the slide rails provide the most effectiveness because the weight of the sled is con centrated in this area however do not place studs closer than 1 to the edge of the track window Polaris Industries Inc 8 73 10 98 BRAKES FINAL DRIVE Traction Polaris Push Through Stud and Skag Recommendations TRAIL AGGR Performance TRACK LUG TUNNEL STUD STUD TRAIL STUD STUD Performance PROTECTOR Qty MEP QTY SKAG indy340 121x15 66 2871689 075 48 B 72 D 99 D 340 Deluxe 12
19. transmission as a unit Slide disc fully over shaft 3 Assemble bolts spring washer and flat washers to transmission and top mounting bracket Items 3 4 5 amp 6 Finger tighten 4 Assemble bolts spacers and cable bracket to top mounting bracket and moveable caliper pad assembly Items 18 7 2 6 amp 20 Position stationary caliper pad assembly inside top mounting bracket pushing bolts through stationary assembly Install spacers and lock nuts on bolts and torque to specification Type WT Adjustment 1 Loosen cable sleeve jam nuts Item 1 and adjust brake cable sleeve to its shortest position A WARNING The following step is critical for proper positioning of the actuating arm to the caliper helix shaft Improper positioning will result in minimal resistance and ineffective brakes 2 With brake lever bottomed on handlebar as if brakes were applied and helix shaft D bottomed in caliper install actuating arm jam nut locking tab jam nut and adjuster bolt Release brake arm slightly to index lever for installation on helix shaft 3 Insert a 015 04 cm feeler gauge between brake disc and moveable brake pad Release brake lever Install return spring Item 13 and finger tighten bolt Item 9 Set adjuster bolt jam nut bend locking tab and remove feeler gauge Friction Pad Air Gap 015 38 mm 4 Field test machine for proper braking action before putting into service If braking action i
20. unit onto right side Notice direction of track rotation for reassembly The arrow in the photo at right indicates track bottom rear of unit 32 Remove front and rear carrier shafts 33 Remove suspension by pulling rear of track out of tunnel Slide suspension forward to driveshaft Lift up and out at the rear NOTE On some models it may be necessary to unhook rear torque arm springs to allow torque arm to lower 34 Inspect transmission brakes suspension and track for excessive wear Check bearings for excessive movement or rough feeling Replace if necessary 10 98 8 54 Polaris Industries Inc BRAKES FINAL DRIVE Transmission Suspension and Track Installation WideTrak LX 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 E track drive lugs DIRECTION OE 4 Install lock collar flangette bearing gasket and i i b ROTATIO flangette on drive shaft positioning bearing flush qe with end of drive shaft 5 Lightly tighten set screws to hold bearing in place 6 Align flangette holes with tunnel 7 Replace adaptor 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
21. 1 10 1 38 kg m using a criss cross pattern Remove dowel from tensioner and install access plug where applicable Install transmission Add 20 oz Premium Synthetic Chaincase Lubricant Transmission Case Bolt Torque 8 10 ft Ibs 1 10 1 38 kg m Photo 2 10 98 8 66 Polaris Industries Inc 8 Install seals shift arm brake disc and caliper Install detent ball spring and spring guide Fill with 20 ounces 600cc Polaris Premium Synthetic Transmission Oil Synthetic Chaincase Lubri Gallon PN2871477 12 oz PN 2871478 Brake Caliper Removal Type WT2 1 2 Remove brake cable Remove retaining bolts making note of location of hex head bolt with flat washer and recessed Allen bolt NOTE Before performing next step note position of two spring clips 3 Remove upper guide bushing and pads Remove lower guide bushing Inspect pads and replace if worn beyond service limit hickness TypeWT2 ervice Limit 250 6 35mm With actuating arm facing up carefully remove tension from the return spring Remove the arm using care not to lose the balls ball spacer or lifter ramp Inspect balls ball spacer lifter ramp and caliper housing for galling or wear Replace if necessary Polaris Industries Inc 8 67 BRAKES FINAL DRIVE Brake Caliper Removal WideTrak LX Minimum Pad Thickness 250 6 35mm 10 98 BRAKES FINAL DRIVE Brake Caliper Assembly WideT
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23. 1 79 Indy XLT Touring 1 3 Pressed Indy 500 XC SP 2 wide 3 Pressed 6 94 6 95 11 79 694 635 1179 Indy 700 XC SP wide Pressed Indy 600 RMK wide 3 Pressed Indy 700 RMK wide 3 Pressed wide Indy 700 SKS Pressed Indy 700 XCR 3 Pressed Indy 800 XCR 3 Pressed Indy Widetrak LX 4 w trak 4 Pressed Denotes driveshafts with press fit bearings on left side no lock collar and flangette studs welded 10 98 8 6 Polaris Industries Inc BRAKES FINAL DRIVE Drive Shaft Sprocket Installation Tips Driveshaft Sprocket Installation All models except WideTraks have a longer spline on the chaincase end of the jackshaft and drive shaft Sprockets must be started from the splined end of the shaft To ensure proper sprocket tooth alignment be sure the vendor logos are oriented in the same position on all sprockets Drive shaft sprocket positions are measured to sprocket hub edge Not idler center For measurements shown below A D see page 8 6 Direction of press of shaft set Direction OI press rebat D r Logo Orientation pu ped Use straight edge against Square 2 Drive Sprocket sprocket hub 4 Drive Sprocket a amp Direction of press of shaft Left Side 2 Drive Sprocket Wide WideTrak LX NOTE When
24. 1x15 66 2871689 075 48 C 72 N 9 J Sp 121x15 71 287191 075 48 b z D 9 P SuperSpot 121x15 82 28754 1 48 c 72 N 9 J xcF 121x15 82 287154 1 48 _ R COMP 72 R COMP 96 S COMP mal 121x15 82 2871544 1 48 N 72 N 9 J ingysoo 121x15 82 2871544 1 48 D 72 o 1200 P 500Classic 121x15 82 287154 1 48 R COMP 72 j R COMP 120 R COMP xiTSP 121x15 82 287154 1 96 R COMP 120 R COMP 144 S COMP XLTClasic 121x15 82 287154 1 96 R COMP 120 R COMP 144 S COMP 500XC 121x15 82 std coolers 1 S00XCSP 121x15 82 R COMP S COMP 600 XC 121x15 91 std coolers 1 075 R COMP 120 S COMP S COMP 600XC SP 121x15 91 sta coolers 1 075 R COMP 120 S COMP S COMP 9 _std coolers 1 96 R COMP 120 R COMP 144 96 L4 96 144 7ooxc 121x15 91 std coolers 1075 96 R COMP 120 S COMP 144 S COMP tas 144 144 7ooxcsP_ 121x15 91 std coolers 1075 96 R COMP 120 S COMP S COMP 440XCR 121x15 82 std cooers 1 96 R COMP 120 S COMP S COMP 700XCR 121x15 91 std 1075 96 R cOMP _120_ S comP S COMP 80 XcR 121x15 91 std 1075 96 r comP 120 S coMP 14 S COMP 340 Touring 133 5x15 82 2871543
25. 4 85 1 83 6 829 808 79 8 idi RISI i Ep 9300 1223 119 4 117 9 1125 107 0 111 9 1059 101 5 101 0 96 1 1956 933 912 9 864 860 845 838 817 807 78 RA 9400 123 6 120 6 119 2 113 7 1082 113 1 107 0 102 6 102 1 97 1 1966 943 922 909 873 869 054 847 826 816 796 796 778 766 745 729 713 69 6 679 A SN 9500 124 9 121 9 120 5 115 0 109 3 114 3 108 2 103 7 103 2 981 977 953 931 29 sa2 le78 863 lese 835 824 805 805 786 774 753 737 721 703 687 4 771 T er 9600 126 3 1232 121 7 116 2 110 5 115 5 109 3 104 8 104 2 99 2 98 7 96 3 94 1 872 865 843 833 813 8t3 794 782 761 745 729 711 69 4 pS H J 193 il LE pen Ji 9700 127 6 124 5 123 0 117 4 111 6 1167 110 4 105 9 105 3 1002 997 97 3 95 1 882 ez4 852 e42 822 e22 802 790 769 752 736 718 1701 9800 128 9 125 8 124 3 nse 1128 1179 1116 107 0 106 4 1012 100 7 98 3 96 1 89 1 88 3 86 1 85 0 82 0 83 0 811 79 5 777 176 0 744 726 70 8 d T M p 9900 1302 127 1 125 5 119 8 113 9 119 4 112 7 108 1 107 5 102 3 1018 994 971 90 0 892 870 859 839 839 819 806 785 768 751 733 715 10000 131 5 128 3 126 8 121 0 115 1 120 3 113 8 109 2 108 6 103 3 102 8 100 4 98 0 909 90 1 87 9 86 8 847 847 827 814 793 776 759 740 1723 eseauieu S29 9 HEYD HAWAI SA peads y
26. 4 5 16 6 8 cm below lip of reservoir opening WARNING Never overfill the reservoir This could alter brake function resulting in system component damage or sever personal injury or death This system also incorporates a diaphragm E as part of the cover gasket and a vent port F located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or contracts Be sure the vent is open and allowed to function If the reservoir is overfilled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system and lead to brake failure Polaris Industries Inc 8 9 10 98 BRAKES FINAL DRIVE Type 3 Master Cylinder Type 3 Master Cylinder Cover Screw Cover Cover Gasket Cylinder Housing Brake Lever Bushing Brake Lever Park Lever Return Spring Pivot Bolt Nut Park Lever Park Lever Pivot Bolt Park Lever Pivot Bushing Spring Seat Washer Compression Spring U Pack Seal Piston O Ring Seal Clamp Bolt Optional Attaching Clamp at customer Lever Pivot Bolt request RELEASE BEFORE Banie perm Baffle Washer OR FIRE MAY RESULT APPLY BRAKE LEVER TO RELEASE DO LED Uv ds WON PARK BRAKE LOCK SM a a Sse dh dl a dl dl SODIDARLNO ine E Park Brake Lever Lock WARNING Release park brake lock before driving or brake sys tem failure or fire may result Apply brake lever to re
27. 814 775 771 753 735 732 725 697 1694 682 676 659 esi 635 635 620 611 595 582 569 555 542 T 7600 100 0 97 5 96 4 920 875 914 86 5 i830 825 785 784 763 745 742 735 706 703 69 1 685 668 660 644 644 629 619 603 589 157 7 56 3 54 9 7700 101 3 1988 976 932 886 926 877 840 836 795 792 773 755 751 745 715 712 700 694 677 1668 652 652 637 627 611 597 584 1 570 556 7800 102 6 100 1 98 9 944 89 8 93 8 888 851 047 806 802 783 765 754 724 724 709 170 3 685 167 7 661 664 1645 163 55 61 9 160 5 159 2 157 8 564 7900 103 9 101 4 100 2 95 6 190 9 950 899 ee2 as l816 812 793 774 764 734 730 718 712 694 686 669 669 653 643 627 613 600 585 571 y z 8000 105 2 102 7 101 4 96 8 92 1 963 ott 873 869 826 822 803 ma 78 1 74 9 1 74 0 72 7 721703 69 4 67 8 67 8 66 2 652 163 4 62 1 60 7 59 2 57 8 8100 106 5 104 0 1027 98 0 932 975 922 884 880 837 833 813 794 790 752 749 736 730 712 703 686 686 670 660 642 628 615 600 585 8200 107 8 1052 104 0 992 944 987 934 895 890 847 843 823 804 800 793 762 7 8 745 1739 720 me 695 695 678 668 es0 636 622 60 7 593 8300 109 2 106 5 105 2 100 4 95 5 999 945 906 901 857 853 833 814 810 803 m 767 754 748 729 720 703 70 3 68 7 676 658 644 630 615 600 T 8400 110 5 107 8 106 5 10
28. AKES FINAL DRIVE Type 3 Drive System Chaincase Assembly 1 Apply Loctite 680 to outer race of new bearing and press into position Press on outer race only or bearing damage may result Loctite 680 PN 2870584 2 Reinstall snap rings 3 Press new seals in until outer edge is flush with chaincase shoulder New seals must be installed from outside of case with lip side in 4 Install chaincase NOTE Do not tighten chaincase bolts at this time Jackshaft Installation 1 Replace seal sleeves and O Rings with new and grease 2 Install jackshaft installation tool on the threads of the jackshaft Jackshaft Installation Tool PN 2870974 13 Tooth Jackshafts PN2871296 15 Tooth Jackshafts Insert jackshaft through bearing in chaincase 4 Install jackshaft alignment tool and secure with castle nut and flat washer Tighten jackshaft nut Securely to ensure positive bearing and jackshaft seating to chaincase NOTE Use of a standard nut and flat washer for this align ment process will simplify the process as well as preserve the locking features of the lock nut for reassembly Jackshaft Alignment Tool a j PN 2870399 13 Tooth Jackshafts PN 2871535 15 Tooth Jackshafts 10 98 8 44 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Drive System Jackshaft Installation Cont 5 If shaft is not centered tap shaft with a soft faced hammer until centered This will align the upp
29. AM resi e a e LI tr IA co ito inni er e cena ee ee ea La 0 de ee E Pr cor 0 e e Li Were _ T_ _ lee ilo sci ENS SE ee ee PA 0 att oo OT RECOMMENDED el Coro AA CCA AS EAS CA CA ARES REA rr CIAO VER TA OE n o Nl EXA AE EAN ACA uu Mir def NOT RECOMMENDED SS e A AAA i a ci use ci ECOS E NOTRECOMMENDED o j Pine ee a Lelio aa EJ EI I E ACT AAA A any E EROS EAS SE TENA A CERA OU RECOMMENDED ee o dic ai e see Pai a ee i 23 o e a eee ri bce ili LL ed Tui EDEN af a der ea a NOT RECOMMENDED 5 CS CGI A AAT ESE ES E TEN AAA ESA ul on ro CEA e e ceo a Sai CT RS ee E _ o e er DIREMO Si 70 10 98 8 4 Polaris Industries Inc BRAKES FINAL DRIVE Sprocket Chain Combinations Sprocket Chain Combinations 7 05 Center Distance Chain Case Acceptable gearing chain combinations are listed below for the 7 05 center distance chaincase Refer to Specifications section of chapter 1 for chaincase center distance by model Combinations listed as not recom mended should not be installed Refer to page 8 4 for 6 5 8 center distance chaincase gearing chain recom mendations fa a tree mmm of Teeth amp of Teeth ES CRI e lr ol ot ca spero 0 eg NOE RECON A Retro rione ict i RENI pui ARA OMM ul lt a i ciale dai ei EE A EI er A e A RORBEGOMMENDED e A A i UA USO IR EEN fe EA CO O E i ARAN EA AMA 2 e APNEA eoo EA
30. C Cleaning and Inspection eee cee eee nes 8 33 Type HSLG Assembly ocio rai PRO mer e Rep eda m ere 8 33 8 34 Type M3 Disassembly hh nnn 8 35 Type M3 Assembly to Chaincase eee eee eee eee 8 36 Type M3 Adjustment iui ines Since wes e er Rx rmn ee Rara s 8 37 Type WT Disassembly 4 rene erm aaa ta 8 38 Type WT Assembly to Transmission 0 LL 8 39 Type WT Adjustment ehh hr 8 39 Type 3 Drive System Disassembly eee 8 40 8 43 Type 3 Drive System Assembly L cee ee eee ce eee eee nes 8 44 8 51 Transmission Suspension and Track Removal WideTrak 8 52 8 54 Transmission Suspension and Track Assembly WideTrak 8 55 8 59 Transmission Disassembly Wide Trak LX eee eee ee 8 60 8 66 Transmission Assembly Wide Trak LX 0c cece eee menor 8 66 8 67 Brake Caliper Removal Type WT2 2 ce eee eee cee eee eee ne 8 67 Brake Caliper Assembly Installation Wide Trak LX 8 68 Reverse Kit Service Tips ccc eee cece mt 8 69 Reverse Kit Maintenance cece eee hh 8 70 8 72 Traction 3 0 nuit Gate alae vidios Aone New RS Welds A MP ERAS 8 73 Stud Recommendations 0 ccc cee cee hh hr 8 74 8 76 ou seujsnpu sue od L8 86 01 INDY JACKSHAFT SPEE VS MILES PER HOUR SPROCKET COMBINATION GEAR RATIO CHAIN PITCH STD CHAINCASE The following chart should b
31. CHAPTER 8 BRAKES FINAL DRIVE Jackshaft Speed vs MPH Chart eee 8 1 8 2 HYVO Chains amp Sprockets cece rr 8 3 Sprocket Chain Combinations 6 5 8 Chaincase 8 4 Sprocket Chain Combinations 7 05 Chaincase 8 5 1999 Track Drive Data iiis TE e a 8 6 Driveshaft Sprocket Installation Tips oo oooooooomcororomommoo 8 7 Track Specifications 2 0 0 0 ccc cece cence sehn 8 8 Hydraulic Brake System Operation eee eee eee ene 8 9 Type 3 Master Cylinder cece cece ee eee eee e 8 10 Type 3 Master Cylinder Inspection and Assembly o oooooomo o 8 11 8 13 Brake Bleeding Fluid Change 0 cece cece eee I 8 14 8 15 Hayes Master Cylinder ccc cee eee cee ee eee Ih 8 16 Hayes Inspection and Replacing Cartridge Subassembly 8 16 8 20 Hayes Master Cylinder Lever and or Pin Replacement 8 21 8 22 Hayes Park Brake Lever and or Spring Replacement 8 23 8 24 Type H4 Friction Pad Replacement ccc eese 8 25 8 26 Type H4 Caliper Disassembly eee eee eee 8 27 Type H4 Cleaning and Inspection c eee eee 8 28 Type HF Assembly cick eee ca cag a pU eR pend e qu RAO RS 8 28 8 29 Type H5LC Friction Pad Replacement L cee eee eens 8 30 8 31 Type H5LC Caliper Disassembly lssseee eee 8 32 Type H5L
32. Cere A i de di ie A I AMEN EIA e NS A II MM CA CAE ei e JNODHECOMMENDED i 99 LONE KEIN OU MENT TEE ERE NEN Tira dg U A die T_T ce 355 37 fe DOUE 59 pue LE UE 70 NOT RECOMMENDED A A OS pr e i lee rr der eR RECOMENDED ea Ta uni To ea ah oa ala ri e a RT ew per Wo uil ou Pa a as A tut ee i p 8 A rr Trana ew TW _ eel a a E NO EEN Polaris Industries Inc 8 5 10 98 BRAKES FINAL DRIVE Specifications 1999 Track Drive Data No of Drive Sprockets Type Bearing Lock Drive Shaft Drive Sprocket Diameter DRIVE SPROCKET POSITION Reference Page 8 7 Indy 340 2 Pressed 6 94 7 48 12 32 All 1999 models 2 3 Pressed 694 748 12 32 sprocket positions Indy 340 Touring 2 3 Pressed 7 48 12 32 Se Ruben Indy Sport 2 3 Pressed 7 48 12 32 not idler center See Indy Sport Touring 2 Pressed 7 48 12 32 page 8 7 Indy TranSport 2 3 Pressed 7 48 12 32 2 Pressed 2 3 Pressed Indy Trail Touring 2 3 Pressed Indy Trail RMK 2 3 Pressed Indy Classic 2 3 Pressed 6 94 7 48 12 32 Indy 500 RMK 2 3 Pressed 6 94 7 48 12 32 indy Classic Touring 2 8 Pressed 694 748 1282 Indy XLT Special 2 wide 3 Pressed 6 94 6 95 11 79 Indy XLT Classic 2 wide 3 Pressed 6 94 6 95 1
33. UTION Incorrect float can cause jackshaft bearings to be side loaded resulting in premature bearing failure 14 Torque driven clutch retaining bolt to specification Driven Clutch Retaining Bolt Torque _ 12 ft Ibs 1 66 kg m 10 98 8 50 Polaris Industries Inc Final Assembly Cont 15 Reinstall air box adjusting box properly 16 Reinstall battery if so equipped Always attach ground cable last to prevent sparks 17 Replace exhaust system 18 Install hood if removed aligning with marks made during disassembly Ensure proper hood closure and readjust if necessary Hood Bolt Torque 8 10 ft Ibs 1 10 1 38 kg m 19 Test ride the unit to ensure all components are functioning properly before putting into service Polaris Industries Inc 8 51 BRAKES FINAL DRIVE Type 3 Drive System 10 98 BRAKES FINAL DRIVE Transmission Suspension and Track Removal WideTrak LX 1 Hood can be removed to prevent damage Mark hood hinges for ease of alignment when reassembling unit 2 Remove battery 3 Turn off fuel valve Move oil tank for access 4 Remove air intake and coolant recovery bottle from its mounting do not remove entirely 5 Remove drive belt 6 Remove driven clutch retaining bolt assembly and drive clutch Note number of spacers which are behind driven clutch for installation during reassembly procedures 7 Remove muffler springs and muffler from unit
34. agm C in reservoir to prevent spills Do not install cover 7 Slowly pump lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever Do not release lever before bleeder screw is tight or air may be drawn into caliper 9 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir Maintain at least 1 2 1 27 cm of brake fluid in the reservoir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose 11 Add brake fluid to the proper level 12 Install diaphragm cover and screws Tighten screws to specification 10 98 8 14 Polaris Industries Inc BRAKES FINAL DRIVE Brake Bleeding System Rebuild Brake Bleeding Fluid Change Cont 13 Field test machine before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar No Closer Than 1 2 1 3 cm 14 Check brake system for fluid leaks Polaris Industries Inc 8 15 10 98 BRAKES FINAL DRIVE Hayes Master Cylinder Hayes Master Cylinder The Hayes brake is standard on all 1999 Gen Il snowmobiles except for Widetrak LX and TranSport Cover Screw Kit Cover Asm Kit Incl 1 3 Cover Gasket Parking Lever Spring Master Cylinder
35. and support rear of unit and align track to specifications found in the Maintenance section Make sure rear idler wheel spacer location is correct before tightening idler wheels 41 Reinstall hood Polaris Industries Inc 8 59 10 98 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX Disassembly Inspection 1 Drain transmission oil into suitable container 2 Remove snap ring spacer washer and brake disc NOTE Note position of spacer washers behind disc for proper alignment upon reassembly 3 Remove detent spring and ball 4 Remove case bolts evenly in a criss cross pattern Polaris Industries Inc 10 98 8 60 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX 5 Tap cases apart with soft faced hammer in the reinforced areas indicated in photo at right Tap end of brake shaft to be sure it remains in case 6 Hold chain tensioner ratchet pawl off ratchet teeth and push tensioner plunger all the way in Insert a 1 8 diameter rod as shown to hold tensioner in released position Remove tensioner assembly Inspect for cracks chipped broken or rounded teeth 7 Remove shift arm 8 Remove shaft and gear assembly from case by tapping with a soft faced hammer evenly on end of shafts 9 Remove output gear assembly and chain Mark chain direction for reference during reassembly Inspect gear teeth for damage Inspect chain for worn cracked or broken link plates
36. balance must be maintained between the number of studs and the length and sharpness of carbide on skags If you are adding studs to the track of a machine it will probably be advisable to add carbide skags or change to more aggressive skags in order to maintain proper vehicle control while turning on hard packed snow or ice If the machine is equipped with carbide skags or if you are adding them or changing to more aggressive skags than standard equipment it may also be necessary to add track studs in order to maintain proper vehicle contro while turning on hard packed snow or ice As a rule of thumb the more studs the longer and sharper the carbide on the skags should be The recommenda tions in the chart on page 8 74 should be used as guidelines in achieving a proper balance of ski and track traction products on Polaris snowmobiles Studs are designed specifically for each riding category They re made in various lengths shapes and materials Improperly applied studs can cause poor traction and premature wear Studs which are too long can cause dam age to the tunnel and heat exchangers Stud points fall into two categories conical and scoopers Conical studs or picks penetrate into the ground for increased traction Scoopers use a flat surface to hold more ground for traction Generally a penetrating point is used for hard ground surfaces and ice Scoopers are used on softer surfaces Material contributes more to stud life and cost than
37. d tighten adjuster and rear shaft bolts to specification 3 8 Suspension Bolt Torque i _ 35 40 ft Ibs 4 83 5 52 kg m 711 6 Suspension Bolt Torque 45 50 ft Ibs 6 21 6 9 kg m Polaris Industries Inc 8 47 10 98 BRAKES FINAL DRIVE Type 3 Drive System Final Assembly 1 Check speedometer cable routing Polaris Cable Lube PN 2870510 2 Grease angle drive and bearing with Polaris grease Polaris Premium All Season Grease PN 2871423 3 Torque bottom chaincase sprocket bolt to specification Bottom Chaincase Sprocket Bolt Torque E 1 19 ft Ibs 2 62 kg m 4 Torque jackshaft nut to specification On models with castle nut if cotter pin does not align tighten nut until it does Apply brake to hold jackshaft while torquing Jackshaft Castle Nut Torque 50 ft Ibs 6 9 kg m 5 To obtain correct chain tension place a slight reverse tension on the chain as indicated in the illustration at right A 6 There should be approximately 1 4 3 8 6 95 cm total deflection on the chain at point B Loosen adjuster bolt locknut and turn adjuster bolt C until correct chain deflection is obtained Chain Deflection 1 4 3 8 6 95 cm 10 98 8 48 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Drive System Final Assembly Cont 7 Tighten adjuster bolt locknut A securely while holding the adjuster bolt B 8 Install chaincase cover gask
38. damage and replace if necessary Type HSLC Assembly 1 Reassemble by reversing disassembly process Be sure all parts are clean and serviceable before reassembling the unit 2 Coata new piston seal in clean DOT 3 brake fluid and place in groove in the caliper bore Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated CAUTION Never reuse an old seal 3 Coat piston thoroughly with brake fluid and work down into bore by hand carefully until bottomed Apply even pressure to avoid cocking the piston in the bore 4 Examine pads for wear or damage If pad thickness is less than 1 32 08 cm install new pads and spring clip assemblies If pads are not worn or damaged they may be reused Be sure pads are reinstalled in their original positions If pads are replaced replace in sets and make sure the new pads have the same friction material type code number as the old set Connect hose or line to caliper Place new pads with friction material facing each other into housing Hold in place using clips Slide brake assembly into bracket until both clips snap into grooves in bracket Separate pads for installation over disc Oo 0 4 9 Place brake assembly over disc and push bracket into chaincase Polaris Industries Inc 8 33 10 98 BRAKES FINAL DRIVE Type H5LC Brake System Type H5LC Assembly Cont 10 Install coolant lines and hose clamps and tigh
39. e Shiny spots on cage indicate wear and the bearing should be replaced Inspect shaft and thrust washers for galling or wear Always replace snap rings if removed Polaris Industries Inc 8 65 BRAKES FINAL DRIVE Transmission Disassembly WideTrak LX 10 98 BRAKES FINAL DRIVE Transmission Disassembly WideTrak Shift Fork Disassembly 1 Remove the detent cam spring and shaft 2 Check condition of key way and key Inspect indicator spring legs and detent areas for wear Replace parts as required NOTE The spring must be pre loaded upon installation Refer to photo and illustration below Transmission Assembly Locate spring in retainer slot as shown Arm of detent plate must be positioned between ends of spring Install key Lubricate all parts before assembly with Premium Synthetic Chaincase Lubricant 1 2 o Install chain on input and reverse shaft Photo 1 Add output gear assembly with chain Photo 2 Photo 1 Add shift fork assembly install entire assembly in case half Lock tensioner plunger in retracted position before installation by installing a 1 8 dowel as shown in photo at right where applicable If washers were removed upon disassembly re install them between tensioner and case Torque bolts to 10 ft Ibs 1 38 kg m Apply 3 Bond 1215 Sealant to case halves Install outer case half and replace brake cable bracket Torque bolts in three steps to 8 10 ft Ibs
40. e assembly NOTE Be prepared to catch brake pads as assembly is lifted out Remove brake pads and inspect for wear and damage Replace if necessary Inspect rotor disc and replace if necessary Polaris Industries Inc 8 35 10 98 BRAKES FINAL DRIVE Type M3 Mechanical Brake System O DNO URN gt Caliper Stationary Cast Puck Moveable Brake Spring Brake Return Bushing Brake Arm Clevis LT Bolt Caliper Brake Disc Seal Jackshaft Brake Cable and Jam Nuts Bracket Brake Washer Washer Spring Lock Bolt Top Mount Bracket Brake Top Mounting Bushing Nut Bi Lock Spacer Alignment Pad Brake Nut Bolt Cable Swivel Retaining Ring O Ring Adjuster Bolt Type M3 Assembly to Chaincase 1 Clip moveable brake pad into position under holder clip Hold moveable and stationary pads in place with a rubber band while placing assembly over rotor disc and mounting to chaincase Remove rubber bands once System is bolted into place Install alignment spacers Item 9 washers Items 3 and 4 and bolts Item 5 Torque assembly to specification Caliper Mounting Bolt Torque 25 30 ft Ibs 3 45 4 14 kg m Loosen cable sleeve jam nuts Item 1 and adjust brake cable sleeve to its shortest position 10 98 8 36 Polaris Industries Inc BRAKES FINAL DRIVE Type M3 Mechanical Brake System Type M3 Brake Adjustment WARNING The following step is critical for proper
41. e used to select optimum gearing for special applications The chart is calculated for models with the P85 drive clutch at a 1 to 1 ratio between drive clutch and driven clutch front drive sprocket diameter is 7 06 inches To use the chart select the jackshaft rpms equal to engine rpm MPH is shown to the right of jackshaft rpm Shown on top is optimum gearing for mph and engine rpms T 20 41 L Gearing 23 37 20 33 21 35 20 35 19 251 21 37 21 39 18 35 20 39 19 39 18 41 17 39 15 35 17 40 17 41 16 39 16 40 14 95 16 41 15 39 15 40 18 41 14 39 14 40 14 41 Ratio 161 165 1 67 175 184 176 186 194 195 2 05 228 229 233 1235 241 244 250 2 50 2 56 260 2 67 2 73 2 79 2 86 2 93 Pitch i sa 66 66 64 66 66 68 le 62 se 66 64 66 62 66 64 64 66 64 64 64 Jackshaft MILES PER HOUR RPM 6500 855 834 824 787 748 782 740 709 706 671 668 652 637 634 628 604 601 59 1 586 57 1 564 551 551 528 529 516 504 493 481 470 RL ina Eee pio 6600 86 8 847 83 7 799 760 794 751 720 717 682 678 662 647 644 63 8
42. emove reservoir cover Using a large hardwood dowel or a C clamp vise grip on the center of the old pads apply pressure toward the caliper piston Compress piston back into caliper assembly Apply pressure slowly to prevent excessive spillage from master cylinder assembly NOTE Pushing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow Remove excess fluid and discard 5 Lift bracket and brake assembly off vehicle Raise open end of cooler and pad assembly to trap antifreeze in cooler and plug the opening of both cooler and engine hose open end 10 98 8 30 Polaris Industries Inc BRAKES FINAL DRIVE Type H5LC Brake System Type H5LC Friction Pad Replacement Cont 6 10 11 12 13 14 15 16 Place new pads with friction material facing each other into housing Hold in place using clips See illustration above Slide brake assembly into bracket until both clips snap into grooves in bracket Clean top of chaincase where brake mounts Separate pads for installation over disc If brake assembly does not slide easily over the disc with loose pads the piston is not compressed far enough into the caliper The caliper assembly must fit freely onto the disc and chaincase Remove plugs Install coolant hose and clamp on cooler assembly Replace 3 8 bolts washers and rope guide Torque to specification Actuate brake several times to set brake pads to proper
43. er chaincase bearing in the chaincase bore 6 Once correct jackshaft alignment has been achieved install lock nuts on chaincase mounting bolts and torque to specification Remove alignment tool from chaincase 7 Install jackshaft flangette gasket and bolts Align grease hole A in bearing with hole or fitting in flangette B to within 100 to ensure greasability Torque nuts to specification Do not lock set screws on retainer ring if so equipped Chaincase Mounting Bolt Torque Flangette Nut Torque 28 30 ft Ibs 3 86 4 14 kg m 15 17 ft Ibs 2 07 2 35 kg m Driveshaft Installation 1 Tip machine back on its left side Set track into machine making note of correct direction of travel Most tracks have an arrow pointing which direction the track turns Polaris Industries Inc 8 45 10 98 BRAKES FINAL DRIVE Type 3 Drive System Driveshaft Installation Cont 2 Insert driveshaft through bearing hole in bulkhead Place inner driveshaft bearing flange bolts in the bulkhead 3 Insert chaincase side of driveshaft through bottom chaincase bearing 4 Tip machine upright Replace speedometer key with a new one and install angle drive Torque nuts to specification Speedometer Angle Drive Mounting Nut Torque 15 17 ft lbs 2 07 2 35 kg m 5 Link together the upper and lower chaincase sprockets with the chain Install both the upper and lower sprockets and chain at the same
44. er in the forward position Clevis Pin Gen II Style 1 Pull shift lever slowly while observing shift arm on transmission 2 lf adjustment is correct the sprockets will mesh fully Shift Lever when the lever is pulled and no grinding will occur Actuator indicating incomplete engagement If incomplete engagement is suspected perform the following steps 1 Move lever to forward position 2 Loosen jam nuts on linkage rod 3 Adjust linkage rod until endplay movement is 1 32 08 cm Do not adjust beyond this point 4 Tighten jam nuts and re check adjustment Reverse Linkage Rod End Play 1 32 08 cm Chaincase Cover Assembly 10 98 8 72 Polaris industries Inc BRAKES FINAL DRIVE Traction The amount of traction required varies depending upon the type of riding and the snowmobile s horsepower WARNING A proper balance of traction products on the skis and track must be maintained to obtain proper vehicle control on hard packed snow and ice Loss of control can result in severe personal injury or death Track studding will enhance braking control on hard packed snow or ice but extreme caution is still required on such surfaces Use extra caution when track studding is employed as steering ability may be reduced on hard packed snow or ice The addition of carbide skags if not already installed is recommended with studded tracks to aid in maintaining proper vehicle steering and control Proper
45. et in chaincase with gap atthe top Install chaincase cover and torque cover bolts to specification Chaincase Cover Bolt Torque Sprocket 8 10 ft Ibs 1 10 1 38 kg m Washer Nut z a AL Seal Sleeve u Brake Hub Cotter Pin 9 Add 9 oz 11 oz on models equipped with reverse of Polaris chaincase oil to the chaincase Verify proper level with dipstick Synth Gearcase Lube 871477 Gallon gt ounces 10 Torque jackshaft bearing set screws to specification if so equipped A tana ackshaft Bearing _ i B Sgt Screw Torque E 80in Ibs 92 kg m 11 Lubricate bearings with Polaris Premium All Season grease Polaris Premium All Season Grease PN 2871423 Polaris Industries Inc 8 49 10 98 BRAKES FINAL DRIVE Type 3 Drive System Final Assembly Cont 12 Reinstall clutch offset washers on jackshaft and install driven clutch Using the clutch alignment tool adjust driven clutch to achieve proper offset Clutch Alignment Tool P90 PN 2870914 P85 PN2870426 P90 Offset 21 32 P90 Electric Start Off set 1 28 straight edge E P85 Offset 5 8 P85 Electric Start Off set 1 straight edge E 13 With proper offset achieved the driven clutch must float on the jackshaft This is done by adding or subtracting spacer washers PN 7555734 to the clutch retaining bolt When properly adjusted the driven clutch will have 020 100 5 2 5 mm float CA
46. eusyoer 3AIHG 1VNI4 SIMVUA BRAKES FINAL DRIVE Jackshaft Speed vs MPH Chart 7 05 Chaincase posee qeu ue e e lO 1 gt E Co duces uod el ei i d e E meme 1 Iv 19 I 1 LI I LS or Jo T 19 J Jackshatt MILES PER HOUR RPM p qe ES ee E memo posee pepe EUH 74 7 70 1 78 8 76 8 71 0 67 1 ni pe ue ns lm 10 98 8 2 Polaris Industries Inc BRAKES FINAL DRIVE HYVO Sprocket Part Numbers HYVO Sprocket Part Numbers Top Sprockets For 3 4 HYVO Drive Systems 3221090 3221091 3221092 HYVO Drive Chain ee EAN Bottom Sprockets For 3 4 HYVO Drive Systems Standard Bottom Sprockets Reverse Sprockets 3222105 1341224 poe Polaris Industries Inc 8 3 10 98 BRAKES FINAL DRIVE Sprocket Chain Combinations Sprocket Chain Combinations 6 5 8 Chain Case Acceptable gearing chain combinations are listed below for the 6 625 center distance chaincase Do not use this chart for models with 7 05 chaincase Refer to page 8 5 for 7 05 chaincase Refer to Specifications section of chapter 1 for chaincase center distance by mode Combinations listed as not recommended should not be installed Ni N D N Upper Sprocket Lower Sprocket Chain Length 62 UMEN LE i ea Crisi fe qe e wormcowwNoD ee e _ O Mo AAA xc rale AN Li ae cile Sl 4 TROT RECOMMENDED i e csi i lati AE CES ___er_i ca ie li pu sl n e ee RECOMENDED
47. ft must be replaced If bearing is rough when turned the bearing must be replaced The bearing is pressed onto the shaft and will require a puller for removal Polaris Industries Inc 8 53 10 98 BRAKES FINAL DRIVE Transmission Suspension and Track Removal WideTrak LX 21 Loosen and remove three carriage bolts and nuts retaining angle drive housing and flangettes 22 Remove angle drive housing adaptor key flangettes gasket and bearing from drive shaft and tunnel NOTE It is not necessary to remove speedometer cable from angle drive Replace adaptor key any time drive train assembly is serviced 23 Tip machine back onto floor 24 Remove right side bumper plug A 25 Remove bolt retaining rear of bumper to foot rest 26 Bend muffler mount out of the way to allow transmission removal 27 Remove three transmission retaining bolts Note all alignment shim quantities and locations for reassembly NOTE Retaining bolts have to be held in place from un derside while removing nuts The lower front bolt cannot be removed at this time It must be lowered to the drive sprocket 28 Lift and maneuver transmission to free drive shaft coupler 29 Lower drive shaft and remove lower front bolt 30 Maneuver transmission until it can be removed from the unit Use care not to damage coolant lines Refer to page 8 61 for transmission disassembly 31 With transmission removed tip
48. he piston with a shop cloth and applying compressed air to the hydraulic inlet port Use only enough air to remove piston Too much pressure may damage piston or bore 9 Using a small wooden or plastic stick work piston seal out from its groove in the piston bore To avoid scratching bore or burring edge of seal groove do not use a metal tool such as a screwdriver 10 Discard old seal 10 98 8 32 Polaris Industries Inc BRAKES FINAL DRIVE Type H5LC Brake System Type HSLC Cleaning and Inspection Check all parts for wear or damage and replace any found to be defective 1 Clean all parts with denatured alcohol and wipe dry with a clean lint free cloth 2 Using compressed air blow out the drilled passages and bores 3 Inspect casting cylinder bore for scoring pitting or corrosion A corroded or deeply scored casting should be replaced Light scores and stains may be removed by polishing with a crocus cloth only Use finger pressure and rotate the crocus cloth in the cylinder bore Do not slide the cloth in and out of the bore under pressure Do not use any other kind of abrasive cloth 4 Check piston to see if it is pitted scored or worn If so discard and replace the piston Do not attempt to polish or sand piston 5 Clean piston with denatured alcohol and wipe dry with a clean lint free cloth Using compressed air blow dry 6 Checkinlet and bleeder hole threads for damage 7 Inspect seat insert for
49. je 610 600 595 580 573 559 559 546 538 529 512 501 489 477 pe y Ed El ds a Gc ji n y 6700 88 1 860 leso 811 771 806 763 731 728 692 689 672 657 654 648 622 ezo 609 604 589 581 567 567 554 546 531 520 509 496 484 6800 894 87 3 5 86 2 82 37 783 181 8 1774 742 738 702 699 68 2 66 7 IC 657 1632 629 618 613 597 590 576 576 56 2 554 539 527 516 50 3 49 1 Lo 6900 90 8 886 875 835 794 830 786 753 749 713 709 692 676 673 667 641 638 1627 622 606 599 584 584 571 562 547 535 524 511 499 7000 921 89 8 88 8 84 7 806 842 797 764 760 723 720 702 686 683 677 65 0 647 636 631 615 607 593 593 57 9 570 555 543 521 518 506 7100 93 4 91 1 90 0 85 9 81 7 85 4 80 8 77 5 77 4 73 3 73 0 71 3 69 6 69 3 68 7 i 65 9 65 7 64 5 64 0 62 4 61 6 60 1 60 1 58 7 57 8 56 3 55 1 53 9 52 6 51 3 7200 947 924 91 3 87 1 829 866 820 786 782 744 740 723 70 6 70 3 69 6 66 9 666 654 649 633 625 610 610 59 6 58 6 571 1558 54 6 533 520 1 A mi j L J L 7300 96 0 937 926 e83 840 87 8 831 797 793 754 750 1733 716 712 706 678 ezs 663 658 641 634 618 fee 604 595 579 566 55 4 540 528 E T 7400 973 95 0 93 8 89 5 852 890 842 808 804 764 761 743 725 722 71 6 687 1684 67 3 66 7 650 642 62 7 1627 1612 603 58 7 57 4 562 54 8 53 5 7500 98 6 96 3 951 908 863 902 854 819
50. justment Due to break in or replacement of components the re verse shift mechanism may require adjustment Adjust with the shifter in the forward position Indy 340 Style 1 Loosen jam nuts on lower end of cable 2 Adjust cable until endplay movement of cable housing at the handlebar bracket is 1 32 08 cm Do not adjust beyond this point 3 Tighten jam nuts and re check adjustment 1 32 Adjustment Reverse CableEndPlay rio or e 08 cm Evolved and Aggressive Style 1 Lift shift lever slowly while observing shift arm on transmission Shift Lever 2 f adjustment is correct shift will move 1 1 1 2 before the shift arm begins to move If adjustment is required proceed with step 3 1 1 1 2 2 5 3 8 cm free play Loosen jam nuts on lower end of cable Chaincase 4 Adjust cable end at transmission until the end of the Cover shift lever has 1 1 1 2 2 5 3 8 cm of freeplay before the cable starts to move the shift arm Do not adjust beyond this point 5 Tighten jam nuts and re check adjustment Reverse Shift Lever Freeplay 1 11 25 3 80m Polaris Industries Inc 8 71 10 98 BRAKES FINAL DRIVE Reverse Kit Maintenance Gen Il Style Oil Change 1 Change annually prior to off season storage Shift Lever Adjustment Due to break in or replacement of components the re verse shift mechanism may require adjustment Adjust with the shift
51. n 1 Install the new lever by actuating the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 2 Align the lever pivot hole with the housing pivot hole 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin down through the hole until the pivot pin snaps into place 4 Reinstall master cylinder assembly 10 98 8 22 Polaris Industries Inc BRAKES FINAL DRIVE Hayes Master Cylinder Park Brake Lever and or Spring Replacement Park Brake Lever and or Spring Removal 1 Remove master cylinder cover screws and cover Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 2 Using a small screwdriver lift long spring arm out of its notch in the housing 3 While pulling in an upward direction with the brake lever slightly activated gently wiggle the park brake lever and spring from its pivot hole Park Brake Lever and or Spring Installation 1 Place the spring on the upper pivot post of the park lever with the formed spring arm fit into its position on the outer part of the park lever The straight spring arm will be pointing towards the back Polaris Industries Inc 8 23 10 98 BRAKES FINAL DRIVE Hayes Master Cylinder Park Brake Lever and or Spring Replacement 2 Rotate the straight spring arm counterclockwise while tilting the park lever down and inserting
52. n floor and tip machine onto left side 9 Remove rear suspension by pulling rear of track outward and sliding suspension forward Lift out rear of suspension first NOTE Unhook the rear torsion springs to relieve pressure on the torque arm for ease of removal Loosen rear shaft bolts and adjuster bolts slide rear shaft forward for ease of removal Chaincase Removal 1 Remove third jackshaft flangette attaching bolt Tip machine back to upright and support rear with jack stand 2 Remove chaincase cover attaching bolts and remove cover Remove cotter pin and nut Loosen chain adjustment bolt and remove chain tensioner assembly 5 Remove bottom sprocket attaching bolt chain and sprockets 6 Remove two bolts securing caliper carrier bracket to chaincase NOTE Inspect brake pad condition and replace if worn to less than 1 2 the original thickness See Brake Pad Re placement in this chapter 7 Remove three chaincase to bulkhead attaching nuts and bolts The front bolt is a through bolt rear and bottom bolts are carriage bolts NOTE On some machines it may be necessary to remove the rear exhaust bracket prior to lifting chaincase or remov ing drive shaft assembly Polaris Industries Inc 8 41 10 98 BRAKES FINAL DRIVE Type 3 Drive System Chaincase Removal Cont 8 Tap on end of driveshaft with a soft face hammer and slide the chaincase off of the driveshaft Remove chaincase Chaincase Bearing
53. n piston ris DOT 3 Brake Fluid 2870990 Install piston assembly into master cylinder service tool until U pack seal is covered by tool as shown NOTE This tool is used to guide the seal lip into the cylinder bore without damage Polaris Industries Inc 8 11 10 98 BRAKES FINAL DRIVE Type 3 Master Cylinder Assembly Assembly Cont 4 Install spring seat washer into bore Insert piston still installed in tool into bore Push piston through special tool Remove tool 5 Reinstall brake lever with bushing bolt and nut 6 Reinstall master cylinder onto handlebar and reconnect brake line Partially insert fittings one to two threads and apply Loctite 242 to remaining threads of fittings Torque brake line fittings to specification Brake Line Fitting Torque Master Cylinder End ugo tight plus2turns Caliper End 12 14 ft Ibs 1 66 1 93 KG m 7 Adjust master cylinder to a level position on handlebar Torque clamp screws to specification T Master Cylinder Clamp Torque 5 55 in Ibs 52 63 kg m 8 Bleed brake system Maintain fluid level in reservoir at 1 4 5 16 6 8 cm below lip of reservoir opening while bleeding brakes Do not allow air into system while bleeding See bleeding procedure on page 8 14 Master Cylinder Fluid Level 1 4 5 1 6 6 8 cm below top of master cylinder 10 98 8 12 Polaris Industries Inc BRAKES FINAL DRIVE T
54. nion Gear Chain Pinion Gear Wide Face Narrow Face Chain Pinion Gear _ Narrow Face Chain Pinion Gear Wide Face ay Spur Pinion Gear j Reverse Kit Option Sprocket Reverse Kit Option Sprocket Spur Pinion Gear Shift Fork Groove Drive Coupler Polaris Industries Inc 8 69 10 98 BRAKES FINAL DRIVE Reverse Kit Maintenance Chain Retention Bracket Washer Washer Pinion Gear Spur Washer Pinion O Ring Gear Drive Compression Spring vA Drive Coupler Retainer Washer Drive Coupler Chain Tension Adjustment 1 Elevate the rear of machine and support so track is off the floor 2 Loosen adjuster bolt lock nut 3 Loosen adjuster bolt slightly about one turn out 4 Tighten adjuster to specified torque 20in lbs 23kgm 5 Loosen adjuster bolt 1 2 turn 6 Hold adjuster bolt in position and tighten locknut securely 10 98 8 70 Polaris Industries Inc BRAKES FINAL DRIVE Reverse Kit Maintenance Cil Level 1 Using Polaris chaincase lubricant maintain proper oil level Proper level is checked by removing dipstick 2 Wipe off any metal particles from the dipstick Small amounts of particles will be common 3 Add lubricant until the level is in the safe zone on the dipstick 11 oz Do not mix or use other types of lubricant Polaris Synthetic Chaincase Lube PN 2871477 Gallon PN 2871478 12 Ounces Ad
55. not compressed far enough into the caliper Caliper assembly must fit freely onto disc and chaincase Replace 3 8 bolts washers and rope guide Torque to specification Actuate brake several times to set brake pads to proper operating position Check for proper fluid level in master cylinder and replace cover Torque cover bolts to specification Inspect entire system for leaks and repair if necessary Field test at low speeds and verify proper brake action If pads drag on disc check caliper and pad assembly 10 98 8 26 Polaris Industries Inc BRAKES FINAL DRIVE Type H4 Brake System Type H4 Caliper Disassembly Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw 0 Caliper 1 Rope Guide WARNING The rider s safety depends on cor rect installation Follow proce dures carefully sii CO ONO I e I Refer to the exploded view above while performing the following steps Remove bracket bolts Disconnect brake line Drain brake fluid into appropriate container and dispose of properly Disassemble on a clean bench PON gt Open bleeder screw and drain brake fluid from caliper assembly into appropriate container Dispose of properly Protect eyes from brake fluid at all times 5 Slide brake assembly out of bracket and remove old pads and clips 6 Place caliper on bench with piston down 7 Remove piston
56. nspection reveals worn damaged or defective parts replacement is necessary in order to avoid serious damage to the machine or injury to the operator ale 2 3 Open adjuster bolt jam nut locking tab A Loosen jam nut and remove adjuster bolt B Remove actuating lever C and return spring Do not disconnect lever arm from cable Remove caliper bolts spacers bracket nuts Items 1 2 7 amp 8 Remove stationary caliper casting and stationary pad Items 10 amp 11 Remove top mounting bolts and washers Items 3 4 amp 5 Pull outward on disc with the balance of the caliper assembly Once disc is free of shaft separate components Remove brake pads and inspect for wear and damage Replace if necessary If stationary pad Item 11 is stuck to stationary casting tap on the side of the pad with a punch and hammer to break it loose Inspect rotor disc and replace if necessary 10 98 8 38 Polaris Industries Inc BRAKES FINAL DRIVE Type WT Mechanical Brake System Type WT Assembly and Installation to Transmission 1 Clip moveable brake pad into position under holder clip Hold moveable and stationary pads in place with a rubber band while placing assembly over rotor disc and mounting to transmission Remove rubber bands once system is bolted into place 2 Apply a light coating of RTV silicone to transmission shaft Position moveable caliper pad assembly along with mounting bracket Item 6 and brake disc onto
57. o a container Unscrew the brake fluid line from the master cylinder outlet using a shop cloth to catch the remaining fluid Drain the fluid from the brake line into the aforementioned container and discard the fluid Inspection NOTE Due to the critical nature of these parts and pro cedures be sure you have thoroughly read and under stand Hydraulic Brake Operation page 8 9 1 Thoroughly clean all brake parts with isopropyl alcoho and either wipe dry with a clean lint free cloth or lightly blow dry with an air hose Examine all parts carefully for signs of excessive wear damage or corrosion Replace any parts found to be damaged Check park lever spring for breakage Replacing Cartridge Subassembly 1 Remove master cylinder assembly as described previously 2 To remove the lever from the housing squeeze the lever handle and actuate the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 3 Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin up throught the hole Remove the pivot pin and the lever Polaris Industries Inc 8 17 10 98 BRAKES FINAL DRIVE Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly 4 Liftthe housing tab on the outlet end of the housing to release the cartridge assembly allowing the cartridge to be pushed out the back of the housing 5 Clean housing bore with alcohol Inspect b
58. olish or sand piston 5 Clean piston with denatured alcohol and wipe dry with a clean lint free cloth Using compressed air blow dry 6 Checkinlet and bleeder hole threads for damage Be sure bleeder screw is clear 7 Inspect brake line seat for damage and replace caliper if necessary Type H4 Assembly 1 Reassemble by reversing disassembly process Be sure all parts are clean and serviceable before reassembling the unit 2 Coata new piston seal in clean DOT 3 brake fluid and place in groove in the caliper piston bore Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated Never reuse an old seal 3 Coat piston thoroughly with brake fluid and work down into bore carefully with a rotating motion until bottomed Apply even pressure to avoid cocking the piston in the bore 10 98 8 28 Polaris Industries Inc BRAKES FINAL DRIVE Type H4 Brake System Type H4 Assembly Cont 1 N gt Qv G9 i I Examine pads for wear or damage If pad thickness is less than 1 32 08 cm install new pad holder assemblies If pads are not worn or damaged they may be reused Be sure pads are reinstalled in their original positions If pads are replaced replace in sets and make sure the new pads have the same friction material type code number as the old set Connect hose or line to caliper Place new pads with friction material facing each other into housing Hold in
59. ompensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located in the brake caliper moves outward and applies pressure to the moveable brake pad This pad contacts the brake disc moves the caliper in its floating bracket and pulls the stationary pad into the brake disc As the lever pressure is increased the braking effect is increased The friction applied to the brake pads will cause the pads to wear As the pads wear the piston within the caliper self adjusts and moves further outward Brake fluid level is critical to proper system operation A low fluid level allows air to enter the system causing the brakes to feel spongy Compensating Port Located within the master cylinder is a small compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the brake lever is released and the piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion caused by heat or contraction caused by cooling During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for the brake fluid to expand Master cylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir 1
60. ore for scratches dents cuts or digs that might cause a leak Replace housing if severe damage is found 6 Paint housing bore and cartridge o rings with D O T 3 brake fluid Polaris DOT 3 Brake Fluid PN 2870990 7 Align slots in cartridge with tabs in housing bore and insert cartridge Push cartridge through until outlet end of cartridge snaps into place 10 98 8 18 Polaris Industries Inc BRAKES FINAL DRIVE Hayes Master Cylinder Inspection and Replacing Cartridge Subassembly 8 Install the lever and pivot pin by actuating the parking brake lever enough distance for the head of the pivot pin to clear the park brake lever 9 Align the lever pivot hole with the housing pivot hole Squeeze the two spring tabs on the end of the pivot pin at the same time pushing the pivot pin down through the pivot hole until the pivot pin snaps into place 10 Apply thread sealant install brake line and tighten snug 11 Mount the master cylinder and switch pack to the handlebars making sure the wires are not pinched or twisted NOTE Start all four screws prior to tightening Tighten tip two screws first followed by bottom two Do not over tighten This will create a gap approximately 050 100 between LH control and master cylinder at the bottom of the assembly There should not be a gap at the top when correct tightening torque sequence has been followed Torque to 24 28 in lbs 27 32 kg m Master Cylinder
61. rak LX Assembly 1 Apply a light film of grease to balls and ball spacer Install in caliper housing 2 Install lifter ramp NOTE Ramp may be installed in any position 3 Install spring and arm with arm located in 8 00 position as shown in photo at right 4 Install lower guide bushing and both spring clips Place pads against lower bushing spring clip and tip into position 5 Install upper guide bushing Installation 6 Install hex head bolt with washer in top guide bushing Install Allen head bolt in recessed bushing as shown 7 Reinstall brake actuating cable and adjust as outlined on page 2 25a of the Maintenance Section Tighten cable lock nuts securely Bracket Move cable up or down in bracket to adjust freeplay 10 98 8 68 Polaris Industries Inc BRAKES FINAL DRIVE Reverse Kit Service Tips The following illustration indicates sprocket position with the Polaris Reverse Kit in the forward and reverse selec tion Installation Tips Refer to Illustration on page 8 70 When installing pinion shaft be sure the chamfered end of pinion shaft is toward case cover Install chain top sprocket bottom option sprocket and wide face pinion gear into case at the same time When installing case cover be sure that shift fork has slipped into fork groove of reverse gear Forward Position Reverse Position Top Sprocket Top Sprocket E P p Sp Drive Chain E Chain Pi
62. s soft re index helix shaft and repeat steps 1 4 Polaris Industries Inc 8 39 10 98 BRAKES FINAL DRIVE Type 3 Drive System Type 3 Drive System Disassembly Except WideTrak The Type 3 drive system is used on all models except the WideTrak This system consists chaincase with right side mounted brake assembly ight side mounted Rear Suspension Removal 1 Mark hood hinges for ease of alignment when reassembling Remove hood to prevent damage air silencer exhaust system and battery if so equipped Place drip pan under chaincase and remove drain plug Dispose of used chaincase oil properly 2 Turn fuel valve off 3 Remove drive belt and driven clutch Note position of washers for controlling drive to driven offset A and washers to control clutch free floating B 4 Loosen jackshaft bearing lock set screws if equipped NOTE Some models are equipped with set screw or Skwez loc style jackshaft bearings Some models are equipped with press fit bearings which have no locking device Set Screw Bearing Press On Bearing Skwez loc Bearing 5 Remove two upper flangette attaching bolts 10 98 8 40 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Drive System Rear Suspension Removal Cont 6 Remove three bolts nuts and washers securing angle drive and bearing flangettes Remove and discard adaptor key 7 Remove four suspension mounting bolts Place a protective mat o
63. tall suspension inside track and align with tunnel mounting holes Instali and hand tighten suspension bolts B Install front carrier shaft assembly inside track and mount to tunnel with bolts Hand tighten bolts Install rear carrier shaft assembly Make sure bolts are not cross threaded and hand tighten A Tip machine back onto floor and tighten all suspension bolts to specification Suspension Bolt Torque 35 40 ft Ibs 4 83 5 52 kg m 10 98 8 56 Polaris Industries Inc BRAKES FINAL DRIVE Transmission Suspension and Track Assembly WideTrak LX Assembly Cont 23 If jackshaft was removed from unit grease coupler spline with Polaris Premium All Season Grease and install on transmission Polaris Premium All Season Grease PN 2871423 24 Check for bearing to bulkhead alignment and shim transmission as required to center jackshaft in bulkhead mount Shims may be required between transmission and bulkhead Seat jackshaft firmly Shim Kit PN 2200126 25 Once properly aligned install flangettes Align grease holes in bearing and flangette 26 Replace nuts holding transmission in place with proper lock nuts and torque to specification Transmission Retaining Nut Torque 28 30 ft Ibs 3 86 4 14 kg m 27 Install bolts and nuts securing flangettes to bulkhead Torque to specification Bearing Flangette Nut Torque 15 17 ft Ibs 2 07 2 35 kg m 28 Set lock ring
64. ten securely 11 Replace 3 8 bolts rope guide and washers Torque to specification Caliper Bolt Torque 25 30 ft Ibs 3 45 4 14 kg m 12 Perform brake bleeding procedure as outlined on pages 8 14 8 15 13 Inspect entire system for leaks 14 Field test at low speeds before putting into regular service 10 98 8 34 Polaris Industries Inc BRAKES FINAL DRIVE Type M3 Mechanical Brake System The Type M3 system is the mechanical brake system used only on Indy 340 models 00 4 OOP com Clevis LT Seal Jackshaft O Ring Brake Cable and Jam Nuts Bracket Brake Washer Washer Spring Lock Bolt Top Mount Bracket Brake Top Mounting Bushing Nut Bi Lock Spacer Alignment Caliper Stationary Cast Pad Brake Puck Moveable Brake Spring Brake Return Nut Bushing Brake Arm Bolt Cable Swivel Bolt Caliper Retaining Ring Brake Disc Adjuster Bolt Type M3 Brake Disassembly Whenever inspection reveals worn damaged or defective parts replacement is necessary in order to avoid serious damage to the machine or injury to the operator 1 2 3 Open adjuster bolt jam nut locking tab A Loosen jam nut and remove adjuster bolt B Remove actuating lever C and return spring Do not detach cable from lever arm Remove top mount bracket and brake assembly mounting bolts Item 5 Remove washers Items 3 and 4 and alignment spacers Item 9 Remove brak
65. the mum pivot post into the pivot hole Pivot Hole Rotate 3 Release the straight arm of the spring and push the park lever pivot post down into position 4 With a small screwdriver push the straight spring arm down until it snaps into the notch in the housing 5 Fill reservoir Replace the master cylinder cover and screws Torque screws to 15 18 in lbs 17 20 kg m Cover Screw Torque 15 18 in Ib 17 20 kg m 10 98 8 24 Polaris Industries Inc BRAKES FINAL DRIVE Type H4 Brake System The Type H4 system is a hydraulic brake The caliper assembly is mounted on the chaincase which allows ease of brake pad and caliper service Measure brake pads from the back of the backing plate to the surface of the friction material as shown in illustration i NOTE Replace pads when worn beyond service limit Minimum Pad Thickness 250 6 35mm Type H4 Friction Pad Replacement Carrier Bracket Attaching Bolts Carrier Bracket Piston Piston Seal Spring Clip Stop Light Switch Brake Pads Brake Line Bleeder Screw 0 Caliper 1 Rope Guide A WARNING 33 OO NO OLB Ni The rider s safety depends on cor rect installation Follow proce dures carefully Protect eyes from brake fluid 1 Clean any dirt from mount bracket and bolts Brake cleaner may be used to aid in cleaning of components 2 With a 9 16 socket remove two 3 8 hex bolts and washers from bracket Remove
66. time Finger tighten the top sprocket nut and turn in bottom sprocket bolt until snug NOTE On Hyvo sprockets the beveled side goes toward the chaincase bearing 6 Install chain tensioner Finger tighten adjustment bolt 7 Install brake caliper assembly in chaincase On models with hydraulic brakes make sure caliper piston is fully retracted into caliper to prevent brake binding from preload of pads On models equipped with mechanical brakes make sure cam is fully re tracted 8 Torque caliper mounting bolts to specification Caliper Mounting Bolt Torque 28 30 ft lbs 3 86 4 14 kg m 10 98 8 46 Polaris Industries Inc BRAKES FINAL DRIVE Type 3 Drive System Track Installation t Tip machine back onto left side Insert suspension rear first into the track 2 Move the suspension back and forth until front torque arm mounting bolts can be started Tighten finger tight 3 Rotate the suspension until the rear mount bolts can be installed in the same manner as the front NOTE For ease of installation turn the front rear scis sor stops FRSS to low position This allows the rear torque arm to move forward more to line up holes 4 Torque suspension mounting bolts to specification 5 Return front rear scissor stops FRSS to original position 6 Install suspension springs FRSS Front Rear Scissor Stop XTRA 10 Shown 7 Align track outlined in suspension section an
67. ype 3 Master Cylinder Assembly Assembly Cont 9 Field test machine before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar Brake Lever Reserve Limit T Not less than We Y 1 3 cm from handlebar a 10 Check brake system for fluid leaks Polaris Industries Inc 8 13 10 98 BRAKES FINAL DRIVE Brake Bleeding Fluid Change Brake Bleeding Fluid Change This procedure should be used to change fluid or bleed brakes during regular maintenance or after complete brake service Brake fluid may damage painted or plastic surfaces Take care not to spill and wipe up any spills immediately Cover parts to avoid damage 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm from reservoir 3 Inspect vent slots A in cover and remove any debris or blockage 4 f changing fluid remove fluid from reservoir with a Mity Vac pump or similar tool CE TN iN RT NOTE Do not remove brake lever when reservoir fluid level is low ro 5 Add brake fluid to within 1 4 5 16 6 8 cm of reservoir top 6 Install a box end wrench on caliper bleeder screw fitting Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on fitting NOTE Fluid may be forced from compensation port B when brake lever is pumped Place diaphr

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