Snowmobile Polaris IQ (2007-2008 year). Instruction - part 43

 

  Index      Snowmobiles / ATV     Snowmobile Polaris IQ - instruction 2007-2008 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  41  42  43  44   ..

 

 

Snowmobile Polaris IQ (2007-2008 year). Instruction - part 43

 

 

6.2

Final Drive and Brakes

GEAR RATIO SPEED CHARTS

8.373 CD Chaincase Speed Charts

Top Gear

26

26

25

25

25

25

25

24

24

23

23

22

22

22

21

21

21

20

20

19

19

19

19

Bottom 

Gear

36

40

36

37

40

41

44

41

42

39

42

39

40

43

40

41

44

41

45

38

41

42

46

Chain

76

78

76

76

78

78

80

78

78

76

78

76

76

78

76

76

78

76

78

74

76

76

78

Gear 

Ratio

1.38 1.54 1.44 1.48 1.60 1.64 1.76 1.71 1.75 1.70 1.83 1.77 1.82 1.95 1.90 1.95 2.10 2.05 2.25 2.00 2.16 2.21 2.42 

Jackshaft 

RPM

MPH at 1 : 1 Clutch Ratio

6000

93 84 89 87 81 79 73 75 74 76 71 73 71 66 68 66 62 63 57 64 60 58 53 

6250

97 87 93 91 84 82 76 79 77 79 74 76 74 69 70 69 64 65 60 67 62 61 55 

6500

101 91 97 94 87 85 79 82 80 82 76 79 77 71 73 72 67 68 62 70 65 63 58 

6750

105 94 101 98 91 88 82 85 83 85 79 82 80 74 76 74 69 71 64 72 67 66 60 

7000

109 98 104 

102 94 92 85 88 86 89 82 85 83 77 79 77 72 73 67 75 70 68 62 

7250

112 

101 

108 

105 97 95 88 91 89 92 85 88 86 80 82 80 74 76 69 78 72 70 64 

7500

116 

105 

112 

109 

101 98 92 94 92 95 88 91 89 82 85 83 77 79 72 81 75 73 67 

7750

120 

108 

116 

112 

104 

101 95 97 95 98 91 94 92 85 87 85 79 81 74 83 77 75 69 

8000

124 

112 

119 

116 

107 

105 98 101 98 101 94 97 95 88 90 88 82 84 76 86 80 78 71 

8250

128 

115 

123 

120 

111 

108 

101 

104 

101 

104 97 100 97 91 93 91 85 86 79 89 82 80 73 

8500

132 119 127 123 114  111 104 107 104 108 100 103 100  93  96  94  87  89  81  91  85  83  75 

8750

136 122 131 127 117 115 107 110 107 111 103 106 103  96  99  96  90  92  84  94  87  85  78 

9000

140 126 134 131 121 118 110 113 110 114 106 109 106  99  101  99  92  94  86  97  90  87  80 

9250

143 129 138 134 124 121 113 116 114 117 109 112 109 102 104 102  95  97  88  99  92  90  82 

9500

147 133 142 138 128 124 116 119 117 120 112 115 112 104 107 105  97  100  91  102  95  92  84 

9750

151 136 145 141 131 128 119 123 120 123 115 118 115 107 110 107 100 102  93  105  97  95  86 

10,000

155 140 149 145 134 131 122 126 123 127 118 121 118 110 113 110 103 105  95  107 100  97  89 

6.3

Final Drive and Brakes

6

DRIVE GEARS AND CHAINS

Drive Gears

CM = Cut Metal Sprocket     PM = Powder Metal Sprocket

Drive Chains

PART NUMBER

DESCRIPTION

3221107

16T. 3/4W, 15 SPL, HYVO, PM

3221093

17T, 3/4W, 15 SPL, HYVO, PM

3221094

18T, 3/4W, 15 SPL, HYVO, PM

3221095

19T, 3/4W, 15 SPL, HYVO, PM

2900003

19T, 3/4W, 15 SPL, HYVO, CM

3221096

20T, 3/4W, 15 SPL, HYVO, PM

2900004

20T, 3/4W, 15 SPL, HYVO, CM

3221097

21T, 3/4W, 15 SPL, HYVO, PM

2900005

21T, 3/4W, 15 SPL, HYVO, CM

3221098

22T, 3/4W, 15 SPL, HYVO, PM

3221099

23T, 3/4W, 15 SPL, HYVO, PM

3221101

24T, 3/4W, 15 SPL, HYVO, PM

3221102

25T, 3/4W, 15 SPL, HYVO, PM

2900009

25T, 3/4W, 15 SPL, HYVO, CM

3222127

26T, 3/4W, 15 SPL, HYVO, PM

3222126

36T, 3/4W, 15 SPL, HYVO, PM

2900010

37T, 3/4W, 15 SPL, HYVO, CM

3222125

37T, 3/4W, 15 SPL, HYVO, PM

2900144

37T, 3/4W, 15 SPL, HYVO, Light Weight

3222129

38T, 3/4W, 15 SPL, HYVO, PM

2900143

38T, 3/4W, 15 SPL, HYVO, Light Weight

3222108

39T, 3/4W, 15 SPL, HYVO, PM

2900012

39T, 3/4W, 15 SPL, HYVO, CM

2900142

39T, 3/4W, 15 SPL, HYVO, Light Weight

3222099

40T, 3/4W, 15 SPL, HYVO, PM

2900141

40T, 3/4W, 15 SPL, HYVO, Light Weight

3222101

41T, 3/4W, 15 SPL, HYVO, PM

2900140

41T, 3/4W, 15 SPL, HYVO, Light Weight

2900139

42T, 3/4W, 15 SPL, HYVO, Light Weight

2900016

43T, 3/4W, 15 SPL, HYVO, CM

3221188

43T, 3/4W, 15 SPL, HYVO, PM

2900138

43T, 3/4W, 15 SPL, HYVO, Light Weight

3222126

45T, 3/4W, 15 SPL, HYVO, Light Weight

PART 

NUMBER

DESCRIPTION

3221114

64P, 3/4W, HYVO CHAIN

3221113

66P, 3/4W, HYVO CHAIN

3221112

68P, 3/4W, HYVO CHAIN

3221115

70P, 3/4W, HYVO CHAIN

3221110

72P, 3/4W, HYVO CHAIN

3221109

74P, 3/4W, HYVO CHAIN

3221108

76P, 3/4W, HYVO CHAIN

3222110

78P, 3/4W, HYVO CHAIN

6.4

Final Drive and Brakes

8.373 CHAINCASE

Assembly View

NOTE:  Verify tensioner bolt seal is flush with mating
surface prior to securing lock nut.
Maintain gear oil level at mid-point of sight glass
with vehicle on level ground.
Install lower gear washer with beveled side out.

A

A

A

B

C

D

G

E

F

T 

A = Cover Fasteners = 10 Ft.Lbs. (12 Nm)

B = Lower Gear Fastener = 19 Ft.Lbs. (26 Nm)

C = Upper Gear Castle Nut = 50 Ft.Lbs. (62 Nm)

D = Fill Plug = 18 - 25 In.Lbs. 

E = Tensioner Bolt = Hand Tight

F = Tensioner Lock Nut = 21 Ft.Lbs. (28 Nm)

G = Drain Plug = 8 Ft.Lbs. (11 Nm)

WARNING

Incorrect chain tension may cause the chain to break 

which may result in the loss of braking control.

CAUTION

Never re-use Cotter pins. Always replace with new 

parts.

Incorrect chain tension may cause the chain to break, 

causing severe chaincase damage.

Installing gear sets not listed on the Gear Ratio Speed 

chart may cause premature gear / chain wear.

6.5

Final Drive and Brakes

6

Chaincase Disassembly

1.

Position the vehicle on level ground. Drain the oil out of
the chaincase into a suitable container. Replace the drain
plug.

2.

Remove the right-side door panel, and exhaust silencer.

3.

Remove the chaincase cover. Un-screw the chain tensioner
bolt.

4.

Remove the cotter pin from the upper gear castle nut and
discard. Lock the parking brake, then remove the castle nut.

5.

Remove the lower gear fastener and washer. Note that
beveled side of the washer faces out.

6.

Remove the chain and upper / lower gears from the
chaincase.

7.

Remove the brake caliper from the chaincase. Secure the
caliper up and away from the chaincase.

8.

Remove the drive belt from the clutches. Remove the
driven clutch.

9.

Raise the rear of the vehicle on a track stand. Loosen the
rear idler wheels and track tension adjusters. Slide the rear
idler shaft completely forward.

10. Remove the speedometer flange / housing from the

bulkhead.

11. Slide the driveshaft out of the chaincase towards the clutch-

side of the vehicle.

NOTE: On some models, it may be necessary to
remove the left-side console storage bucket.

12. Remove the nuts securing the chaincase to the frame.

Carefully pull the chaincase away from the jackshaft, then
out of the engine compartment.

13. To replace the seals and bearings, carefully pry out the seals

from the backside of the chaincase and discard.

14. Remove the two snap rings securing the bearings inside the

case.

15. Press on the outer race of each bearing from the backside

of the case to remove each bearing.

16. To install the bearing, press on the bearing outer race from

the inside of the cover until fully seated. Install the snap ring
making sure it is seated in the groove.

17. Lightly coat the outer edge of each new seal with oil, then

install with the seal lips facing each bearing from the
backside of the case.

18. Inspect the jackshaft seal sleeve for abnormal wear and tear.

Replace the o ring with a new part.

Chaincase Assembly

1.

Install a the jackshaft seal sleeve and a new o ring on the
jackshaft.

2.

Install the jackshaft installation tool, PN 2871296, on to the
end of the jackshaft, or wrap electrical tape over the
jackshaft splines.

3.

Carefully re-install the chaincase. Install the chaincase
fasteners and nuts. Hand-tighten the nuts so that the
chaincase can still be moved.

4.

Install the driveshaft back into the chaincase.

5.

Remove the jackshaft installation tool from the jackshaft,
then install the jackshaft alignment tool, PN 2871535, on
to the jackshaft.

6.

Torque all of the chaincase fasteners to specification using
a criss-cross pattern.

7.

Remove the jackshaft alignment tool. Install the brake
caliper and torque fasteners to specification.

8.

Torque speedometer / driveshaft flange nuts and torque to
specification.

9.

Torque speedometer housing nuts to specification.

10. Lock the parking brake.

CAUTION

Do not kink or bend the brake hose.

CAUTION

Always press on the outer race of the bearings.

T 

Chaincase Mounting Fasteners

28 Ft.Lbs. (38 Nm)

DO NOT OVER-TORQUE FASTENERS

T 

Brake Caliper Mounting Fasteners

19 - 21 Ft.Lbs. (26 - 28 Nm)

T 

Speedometer / Driveshaft Nuts

17 Ft.Lbs. (23 Nm)

T 

Speedometer Housing Nuts

17 Ft.Lbs. (23 Nm)

 

 

 

 

 

 

 

Content   ..  41  42  43  44   ..