Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 39

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 39

 

 

7.3

Final Drive and Brake Systems

7

Rev. 1 07/2006

FINAL DRIVE GEAR RATIO

Speed Chart

Reference the speed chart to determine which upper and lower
gears can be installed in the chaincase, and to determine the
mathematical vehicle speed for each ratio.

Chaincase Speed Chart

Top Gear

26

25

24

24

24

23

22

21

21

Bottom Gear

39

40

44

40

41

46

46

46

47

8.424

78

78

80

78

78

80

80

80

80

Gear 

Ratio

1.50 1.60 1.83

1.67 1.71 2.00 2.09 2.19 2.24 

Jackshaft RPM @ 1:1 Drive Clutch / Driven Clutch Ratio (Clutches spinning at the same speed.)

6000

86 81 71

77 75 64 62 59 58 

6250

89 84 74

81 79 67 64 61 60 

6500

93 87 76

84 82 70 67 64 62 

6750

97 91 79

87 85 72 69 66 65 

7000

100 94 82

90 88 75 72 69 67 

7250

104 97 85

93 91 78 74 71 70 

7500

107 

101 88

97 94 81 77 74 72 

7750

111 

104 91

100 97 83 80 76 74 

8000

115 107 94

103 101 86  82  78  77 

8250

118 

111 97

106 

104 89 85 81 79 

8500

122 114 100

110 107  91  87  83  82 

8750

125 

117 

103

113 

110 94 90 86 84 

9000

129 

121 

106

116 

113 97 92 88 86 

9250

132 

124 

109

119 

116 99 95 91 89 

9500

136 128 112

122 119 102  98  93  91 

9750

140 131 115

126 123 105 100  96  94 

10000

143 134 118

129 126 107 103  98  96 

7.4

Final Drive and Brake Systems

Rev. 1 07/2006

FS / FST CHAINCASE

Drive Chain Deflection Adjustment

1.

Raise the track up off of the ground using a track stand or
similar stand.

2.

Open hood, and clutch-side door panel.

3.

Rotate the driven clutch in forward (counter-clockwise)
direction. 

4.

While holding the driven clutch, lock the parking brake.

5.

Open the exhaust-side door panel.

6.

Remove the springs and nuts securing the exhaust silencer
to the chassis, then remove the silencer.

7.

Loosen the chain tensioner jam nut. Back the adjuster screw
out a few turns, then turn the screw in, by hand, until it no
longer can be turned.

8.

Back-out the adjuster screw 1/4 turn, then lock jam nut.

9.

Reinstall the exhaust silencer, springs, and retaining nuts.

10. Release the parking brake.

11. Close compartment doors, and hood. Place the track back

on the ground.

Chaincase Oil Level

To ensure proper operation, the oil level must be maintained in
the “SAFE” zone on the dipstick.

• A = Dipstick

• B = SAFE Level Marks

T 

Chain Tensioner Jam Nut

18 - 23 Ft.Lb. (24 - 31 Nm)

JAM NUT

ADJUSTER SCREW

7.5

Final Drive and Brake Systems

7

Rev. 1 07/2006

Chaincase Oil Drain

A drain plug is located on the bottom of the chaincase and can
be accessed through the nosepan.

• A = Drain Plug

Chaincase Disassembly

1.

Drain the oil from the chaincase. Reinstall the drain plug.

2.

Remove the exhaust silencer.

3.

Remove the reverse motor.

4.

Disconnect the forward and reverse limit switches.

5.

Remove the cover, washer, and spur gear from the
chaincase.

NOTE:  The spur gear and washer may drop out with
the chaincase cover.

6.

Extract the following parts from inside the chaincase:

• Shift Fork Assembly

• Pinion Gear

• Indicator Hub w/Shift Shaft

• Reverse Gear w/Washer

T 

Chaincase Drain Plug

8 Ft.Lb. (11 Nm)

7.6

Final Drive and Brake Systems

Rev. 1 07/2006

7.

Loosen the chain tensioner jam nut, then back out the
tensioner screw to allow for the removal of the tensioner
pad.

8.

To remove the gears and drive chain, remove the upper and
lower gear snap rings. Extract the upper and lower gears.

9.

To remove the upper hub carrier:

• Remove the console.

• Remove the seat, seat assemblies, and fuel tank 

assembly.

• Locate the snap ring on the backside of the brake disc. 

Remove the snap ring using a heavy duty, 90

°

 snap ring 

pliers.

• Remove the upper hub carrier snap ring.

• Carefully slide the hub carrier out of the chaincase.

10. To remove the lower hub carrier:

• Remove the snap ring, then extract the hub carrier from 

the chaincase.

11. To remove the chaincase housing:

• Suspend the engine inside the engine compartment. See 

“Suspending Engine” on page 5.2.

• Remove the fastener securing the housing to the 

bulkhead.

12. Remove the brake caliper assembly.

13. To remove the oil seals, use a pick or scribe to carefully

extract each seal.

14. To reinstall a new seal, carefully press the outside diameter

of the seal into the bore until it is fully seated.

15. Apply a small amount of grease to the inner seal lip.

16. To reinstall the chaincase housing:

• Loosely install the 5 fasteners that secure the housing to 

the bulkhead.

• Torque the lower 2 fasteners to 28 Ft.Lbs. (38 Nm).

• Torque the upper-left fastener and the 2 upper-right 

housing/engine strap fasteners to 14 Ft.Lbs.(19 Nm).

• Torque the lower housing/engine strap fastener to 22 

Ft.Lbs. (30 Nm).

• Torque the brake caliper mounting fasteners to 20 

Ft.Lbs. (27 Nm).

 

 

 

 

 

 

 

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