2007-2011 IQ Service Manual Chapter 06
Contents
1. 6 24 CALIPER REMOVAL Ricarica pa RET EX SEI 6 24 CALIPER 1 6 25 CALIPER ASSEMBLY wane donne ee Ea 6 25 BRAKE CALIPER PISTON AND SEAL 6 25 BRAKE PAD REPLACEMENT 6 26 BRAKE DISC 1 6 26 TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 6 1 Final Drive and Brakes GEAR RATIO SPEED CHARTS 8 373 CD Chaincase Speed Chart 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 2 MPH at 1 1 Clutch Rati RPM at Clutch Ratio 6000 93 84 89 87 81 79 73 75 74 76 71 73 71 66 68 66 622. 2 4 6 11 GEARCASE MOUNTING 1 6 11 GEAR SELECTOR 1 6 12 GEAR SELECTOR LINKAGE ADJUSTMENT 6 12 GEAR GASE REMOVAL indc libel we eR e epu E A 6 13 INSPECTION 4 e eR RI due erum 6 13 INPUT SHAFT INSPECTION 4 6 16 LOW GEAR SHAFT 6 16 OUTPUT SHAFT 4 6 17 SHIFT DRUM 1 6 17 GEARCASE 5 6 18 GEARCASE 6 19 BRAKE SYSTEM praeent asn dann mien Bane oe ae aos e toda 6 20 OVERVIEW T wet od E en 6 20 COMPENSATING PORT Re ed 6 20 GENERAL GUIDELINES pra rodai d tS ble ge 6 21 BRAKE FLUID REPLACEMENT amp BLEEDING 6 21 MASTER CYLINDER LEVER 6 22 CYCLONE MASTER CYLINDER LEVER SERVICE 6 23 BRAKE LINE 6 23 BRAKE LIGHT SWITCH
3. Do not use brake fluid taken from old used or unsealed containers Never reuse brake fluid A CAUTION Pressure bleeding is not recommended When fluid surges through the fittings itis possible to cavitate the fluid and create air in the system In addition the fluid stored in a pressure bleeder may be contaminated Al ways use fresh DOT 4 brake fluid from a sealed con tainer Keep these points in mind when bleeding hydraulic brakes The master cylinder reservoirs have limited capacities It is easy to empty them during the bleeding procedure This introduces air into the system which you are trying to purge Watch the reservoir closely and add fluid when necessary to prevent air from entering the system TERRAIN DOMINATION Apply only light to moderate pressure to the lever or pedal when bleeding the brake system Extreme pressure will cause a surge of fluid through the small orifices of the brake system when the bleeder screw is opened and introduce air into the system by means of cavitation Small amounts of air can become trapped in the banjo bolt fittings at the master cylinder s and junction points of brake lines These fittings can be purged of air by following a standard bleeding procedure at these fittings instead of the bleed Screw on caliper if necessary to speed the bleeding process This is usually only needed if system was completely drained of fluid Bleed each line connection star
4. 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 CAUTION Always press on the outer race of the bearings 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 TERRAIN DOMINATION POLARIS 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
5. X 7 9 O E 7 c ROD LINKAGE A 5 Ft Lbs 7 Nm B 7 Ft Lbs 9 5 Nm C 15 Ft Lbs 20 Nm Gear Selector Linkage Adjustment 1 Adjust length of upper linkage so shift lever can move freely from point A to point B without contacting points C or D 2 There should be a minimum 1 8 gap between the shift lever and shift slot when shifted into high or low gear E 3 Torque linkage jam nuts to 8 14 ft lbs 11 19 Nm when adjustment is correct A B x D 144 MINIMUM GAP 1 8 46 MINIMUM GAP 1 8 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS 6 12 Final Drive and Brakes Gear Case Removal 1 Open the hood and remove the engine compartment doors 2 Remove exhaust resonator 3 Remove the brake caliper from the gearcase cover Secure the caliper up and away from gearcase without binding the brake fluid hose 4 Note location of shift linkage on transmission to assure proper location during reassembly Remove cotter pin washers and pin from transmission arm Pn LLL Www 5 Remove REVERSE light wire connector from sensor 6 Remove angle drive housing adaptor key flangette gasket and bearing from drive shaft and tunnel 7 Remove three transmission retaining bolts Note all alignment shim quantities locations for reassembl
6. 3222101 41T 3 4W 15 SPL HYVO PM 3221188 43T 3 4W 15 SPL HYVO CM Cut Metal Sprocket Powder Metal Sprocket Drive Chains PART NUMBER DESCRIPTION 3221109 74P 3 4W HYVO CHAIN 3221108 76P 3 4W HYVO CHAIN 3222110 78P 3 4W HYVO CHAIN l 9922854 2007 2011 IQ Service M 6 3 lt gt POLRHRIS 2010 Polaris Sales Ine 272 Final Drive Brakes 8 373 CHAINCASE Assembly View VENT FILL PLUG gt 4 Qr CHAINCASE b SAAN BEARING SNAPRING MAGNETICDRAIN PLUG GEAR WASHER TENSIONER BLOCK BEARING _ 7 j p Sige E FASTENER SEAL LOCK NUT TENSIONER BOLT F FASTENER ey 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 A WARNING which may result in the loss of braking control Incorrect chain tension may cause the chain to break 6 4 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 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 ge
7. Be sure the vent is open and allowed to function If the reservoir is overfilled orthe diaphragm ventis plugged the expanding fluid may build pressure in the brake system and lead to brake failure TERRAIN DOMINATION POLARIS Final Drive and Brakes General Guidelines A WARNING An unsafe condition exists when air is trapped in the hydraulic brake system Air in the brake hydraulic system acts like a soft spring and absorbs a large percentage of the pressure developed by the master cylinder Without this pressure the braking system cannot develop full braking force to allow for safe controlled stops It is extremely important to bleed the brakes properly after any brake system work has been performed or when inspection reveals spongy brakes A soft spongy feeling in the brake lever and or brake pedal could indicate a hazardous condition in the brake system Do not operate the vehicle until the failure in the brake system is corrected Keep brake fluid tightly sealed and out of reach of children Brake fluid can accumulate moisture reducing it s effectiveness Contaminated brake discs or brake pads greatly reduce braking performance and increase stopping distance Do not attempt to clean contaminated pads Replace them Clean the brake disc with brake cleaner This brake system requires ethylene glycol based fluid DOT 4 Do not use or mix different types of fluid such as silicone based or petroleum based
8. Chaincase Mounting Nuts 28 Ft Lbs 88 Nm F Speedometer Sensor Screw 5 Ft Lbs 7 Nm G Speedometer Gear Screw 15 Ft Lbs 11 Nm CAUTION Do not over torque the chaincase mounting nuts 6 8 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc NOTE Set driven clutch offset following procedure in the PVT System Chapter Lubricate components as outlined in the Periodic Maintenance Table Tighten chaincase mounting nuts using a criss cross pattern Install jackshaft seal sleeve with beveled edge towards brake disc then install o ring inside sleeve TERRAIN DOMINATION POLARIS Final Drive and Brakes Jackshaft Removal N OER gros 11 12 13 14 15 Remove the drive belt and driven clutch Note of the number and location of the driven clutch spacers washers Drain the chaincase lubricant Remove the chaincase cover Remove the cotter pin on the upper sprocket Apply parking brake Remove the upper sprocket nut Remove the lower sprocket retaining bolt Loosen the chain tensioner Remove the upper and lower sprockets and chain from chaincase Release the parking brake Remove the bearing flange on the driven clutch side Remove the jackshaft assembly from the brake disc and chassis by tapping on the end of the jackshaft with a soft face hammer This will also remove the o ring and seal Inspect jackshaft in bearing contact area
9. Remove the brake and parking brake levers Disconnect the brake hose from the cartridge Carefully pop the cartridge out of the housing To install the cartridge lubricate the entire surface with DOT 4 brake fluid Align the cartridge with the housing tabs then firmly press the cartridge back into the housing until the cartridge is engaged with the tabs Refill and bleed the brakes system as outlined in this chapter See Brake Fluid Replacement amp Bleeding on page 6 21 TERRAIN DOMINATION POLARIS Final Drive and Brakes Cyclone Master Cylinder Lever Service Brake Line Replacement COVER SCREWS E CLIP A Banjo Bolt 240 264 In Lbs 27 29 Nm Cover Screws 6 8 In Lbs 7 9 Nm C Handlebar Clamp 60 80 In Lbs 6 7 9 Nm 1 Toremove the brake lever remove the e clip from the lever pin 2 Extract the pin from the housing then remove the lever 3 Disconnect the brake hose from the master cylinder assembly 4 The master cylinder assembly is not serviceable Master cylinder reconditioning requires complete replacement 5 Refill and bleed the brakes system as outlined in this chapter See Brake Fluid Replacement amp Bleeding on page 6 21 TERRAIN DOMINATION POLARIS brake light switch Follow these steps if the brake line is to be replaced 1 Ifneeded bleed the brake system by attaching a clear hos
10. pre loaded upon installation Refer to illustration SPRING TABS SHAFT MUST BE IN PLACE WHEN INSTALLING SPRING SHIFT INDEX 6 17 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc Final Drive and Brakes Gearcase Assembly Lubricate all parts before assembly with 80W SCL lubricant NOTE Wrap input low gear and output shaft spline ends with electrical tape to prevent seal damage during assembly 1 Ifthe oil deflector was removed from the outer cover apply Loctite 242 to screw threads and torque to specification 6 1 Cil Deflector Screws 8 Ft Lbs 11 Nm Apply Loctite 242 Install chain on input and low gear shaft Add output gear assembly with chain Add shift fork assembly Install entire assembly in case half making sure the splines do not damage the case seals 6 Clean mating surfaces with alcohol or acetone Apply Loctite 5699 Flange Sealant to the case mating surfaces 7 Install outer case Torque bolts to specification using specified pattern c RON c a Q OYN d 3 n Gearcase Case Fasteners 9 Ft Lbs 12 Nm 6 18 8 Install brake disc Install detent ball spring and plug Torque detent plug to specification T Detent Plug 12 Ft Lbs 16 Nm Apply pipe sealant to threads 9 Install the gear selector bell crank Torque screw to specification T Bellcrank Scr
11. 4 FASTENER 02 gt i KEY i BEARING DRIVESHAFT FASTENER NUT NOTE Set driven clutch offset following procedure the PVT System Chapter Lubricate components as outlined in the Periodic A Driven Clutch Fastener 17 Ft Lbs 23 Nm Maintenance Table B Jackshaft Flange Nuts 17 Ft Lbs 23 Nm Tighten chaincase mounting nuts using a criss C Speedometer Housing Nuts 17 Ft Lbs 23 Nm cross pattern D Driveshaft Housing Nuts 17 Ft Lbs 23 Nm Install jackshaft seal sleeve with beveled edge E Chaincase Mounting Nuts 28 Ft Lbs 38 Nm towards brake disc then install o ring inside sleeve CAUTION Do not over torque the chaincase mounting nuts TERRAIN POLARIS DOMINATION 6 7 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Final Drive and Brakes Electronic Speedometer Drive Train Assembly N WASHERS e BELT Og SPACER 4 3 4 5 6 NI 9 ANGE WASHERS DRIVEN CLUTCH A B OR lt gt 22 JACKSHAFT lt BRAKE DISC FLANGE SEAL SLEEVE FLANGE 0 Be iv UA SNAP RING oS Se poi SPEEDOMETER SENSOR we gt A DRIVESHAFT Q CHAINCASE ey T A Driven Clutch Fastener 17 Ft Lbs 23 Nm B Jackshaft Flange Nuts 17 Ft Lbs 23 Nm C Speedometer Housing Nuts 17 Ft Lbs 23 Nm D Driveshaft Housing Nuts 17 Ft Lbs 23 Nm E
12. 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 10
13. 9 106 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 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc 6 2 Final Drive and Brakes DRIVE GEARS AND CHAINS Drive Gears PART NUMBER DESCRIPTION 3221093 17T 3 4W 15 SPL HYVO 3221094 18T 3 4W 15 SPL HYVO 3221095 19T 3 4W 15 SPL HYVO PM 3221096 20T 3 4W 15 SPL HYVO PM 3221097 21T 3 4W 15 SPL HYVO PM 3221098 22T 3 4W 15 SPL HYVO 3221099 23T 3 4W 15 SPL HYVO 3221101 24T 3 4W 15 SPL HYVO PM 3221102 25T 3 4W 15 SPL HYVO PM 3222127 26T 3 4W 15 SPL HYVO PM 3222126 36T 3 4W 15 SPL HYVO PM 3222125 37T 3 4W 15 SPL HYVO PM 3222108 39T 3 4W 15 SPL HYVO PM 3222099 40T 3 4W 15 SPL HYVO PM
14. Final Drive and Brakes CHAPTER 6 Final Drive and Brakes GEAR RATIO SPEED GHAHTS gt VEG ee bee eee Re RC ep x a ee 6 2 8 373 CD CHAINCASE SPEED 6 2 DRIVE GEARS AND dn Re oe de eR 6 3 DRIVE GEARS uh Dh READER ER aoa eee E 6 3 DRIVE CHAINS cae eie Rd e dE t irn 6 3 8 373 GHAINOASE ewe caes wp dade 6 4 ASSEMBLY VIEW EINER ER EEUU DNI ING 6 4 CHAINCASE 5 6 5 CHAINCASE 6 5 DRIVETRAIN wc dora UNIUS Recon e Wate OR CERT UNUS 6 7 SPEEDOMETER CABLE TYPE DRIVE TRAIN 6 7 ELECTRONIC SPEEDOMETER DRIVE TRAIN 6 8 JACKSHAFT 6 9 JACKSHAFT 6 9 DRIVESHAFT 6 9 lO WIDETRAK GEAR GASES e ees Qs pe had aot Jo PSSM 6 10 DRIVESHAFT AND 6 10 GEARCASE OIL LEVEL 6 11 GEARCASE OIL
15. If diameter is 0 001 025 mm less than non contact area replace the jackshaft Jackshaft Installation 15 2 10 11 12 TERRAIN DOMINATION Install jackshaft installation tool PN 2871296 onto the threads of the jackshaft Insert the jackshaft assembly through the brake disc and install a new o ring and seal sleeve Push jackshaft through chaincase Remove the jackshaft installation tool With the jackshaft through the chaincase install the jackshaft alignment tool PN 2871535 and secure with the flat washer and castle nut Tighten the castle nut securely to ensure positive bearing and jackshaft seating to chaincase If shaft is not centered tap shaft with a soft faced hammer until centered This will align the upper chaincase bearing in the chaincase bore Once the correct jackshaft alignment has been achieved install lock nuts on the chaincase mounting bolts and torque them to 20 ft Ib 27 N m Remove the jackshaft alignment tool from chaincase Install jackshaft flangette and bolts Align grease hole in bearing with hole or fitting in flangette Torque nuts to 11 ft Ib 15 N m Place the same amount of washers on the drive clutch end of the jackshaft Install the driven clutch spacer and washers and torque the retaining bolt to 17 ft lb 23 N m Install the belt POLARIS Driveshaft Removal Installation 1 Remove the side panels 2 Remove the intake plenum 3 Remove t
16. a 3 16 Allen wrench Drain Polaris 80W Synthetic Chaincase Lubricant all of the oil into the drain pan Dispose of the used oil appropriately 4 Reinstall the drain plug Torque plug to 6 10 Ft Lbs Magnetic Plug 8 13 Nm AAE 5 Remove the dipstick and fill the gearcase with new oil ASEA Do not overfill p NOTE Always clean the magnetic plug when PP e dipstick is removed and at 500 mile intervals Gearcase Mounting Position the vehicle on a flat level surface 2 Remove the dipstick and wipe clean Reinstall the dipstick 3 Remove the dipstick and verify oil level Add recommended oil at the dipstick hole if needed Do not overfill NOTE Always clean the magnetic plug when dipstick is removed and at 500 mile intervals Gearcase Oil Change Gearcase Oil Polaris 80W Synthetic Chaincase Lubricant Gearcase Fluid Capacity 20 oz 28 Ft lbs 38Nm TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 02010 Polaris Sales Inc 6 11 Final Drive and Brakes Gear Selector Assembly lt lt 2 SHIFT LEVER GEAR SELECT KNOB 55 SHIFT GUIDE JN LEZA T SHIFT MOUNT 4 D eu t C 4 SPACER o ur D d gt 5 2 9B y SN S S WAVE WASHER Bo A ROPE GUIDE UPPER LINKAGE L RECOIL MOUNT CN d SRS yt Bo r D BUSHING 0 IR ROLLER
17. 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 ey T Chaincase Mounting Fasteners 28 Ft Lbs 38 Nm DO NOT OVER TORQUE FASTENERS 7 Remove the jackshaft alignment tool Install the brake caliper and torque fasteners to specification e T Brake Caliper Mounting Fasteners 19 21 Ft Lbs 26 28 Nm 8 Torque speedometer driveshaft flange nuts and torque to specification e T Speedometer Driveshaft Nuts 17 Ft Lbs 23 Nm 9 Torque speedometer housing nuts to specification 10 Lock the parking brake ey T Speedometer Housing Nuts 17 Ft Lbs 23 Nm 6 5 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc Final Drive and Brakes 11 Reinstall the chain and upper lower gears Install the lower gear washer with the beveled side facing out Torque castle nut and lower gear fastener to specifications 6 1 Upper Gear Castle Nut 50 Ft Lbs 68 Nm Do not back nut off only to align cotter pin holes with nut Lower Gear Fastener 19 Ft Lbs 26 Nm 12 Turn the chain tensioner bolt in until there is 0 25 in 6 35mm deflection
18. ar chain wear 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 Some models feature a magnesium cover Magnesium covers do not feature a bracket Magnesium covers cannot be installed on 2006 2008 chain cases TERRAIN DOMINATION POLARIS Final Drive and Brakes 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 Removethe brake caliper from the chaincase Secure the caliper up and away from the chaincase Do not kink or bend the brake hose 8 Remove the drive belt from the clutches Remove the driven clutch 9 Raisethe 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
19. between the backside of the chain and the chaincase he NO LA n mm Drive Chain Deflection 0 25in 6 35mm 13 Turn the tensioner bolt seal down into the chaincase Torque the tensioner bolt jam nut to specification ey T Tensioner Jam Nut 21 Ft lbs 28 Nm 14 Verify the cover seal is in good condition Install the cover and bracket Torque fasteners to specification using a criss cross pattern ey T Chaincase Cover Fasteners 10 Ft Lbs 13 Nm 15 Fill the chaincase with new chaincase oil until the level is at the mid point of the sight glass Chaincase Oil Polaris 80W Synthetic Chaincase Lubricant 5 6 Chaincase Fluid Capacity 110z 325 3 ml 6 6 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc 16 Reinstall the exhaust silencer and door panel 17 Reference the PVT System and Front and Rear Suspensions chapters for idler shaft torque and PVT System assembly information TERRAIN DOMINATION POLARIS Final Drive and Brakes DRIVE TRAIN Speedometer Cable Type Drive Train Assembly SPACER BELT FASTENER T die 6 j FASTENER WASHERS ELANCE BEARING EI 900 5 WASHERS Pe x JACKSHAFT K RETAINING RING P MIS SEAL SLEEVE SPEEDOMETER DRIVE BUSHING j i em g O RING FLANGE i 6 C e T e So X 5271 fu HOUSING GASKET
20. brake system if required 18 Fill and bleed the brake system of air See Brake Fluid Replacement amp Bleeding on page 6 21 19 Test the snowmobile at low speed to verify operation Brake Pad Replacement Brake Pad Brake pads need to be replaced if the total thickness of the pads and backing are less than 250 6 35mm 1 Remove brake pad retaining pin 3 2 Remove the brake pads 4 3 Inspect the brake disc 5 for any wear 4 Replace brake pads in reverse order of removal 250 6 35mm Brake Disc Replacement The brake disc should be replaced if the thickness of the disc is below 193 49cm Remove the chaincase Slide the brake disc from the jackshaft Check the jackshaft for any damage Replace the o ring on the jackshaft Replace the brake disk Assemble the chaincase o gud omi DOMINAT POLARI
21. ct chain for worn cracked or broken link plates i 10 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 7 Extract the complete chain gear assembly from the gearcase housing TERRAIN DOMINATION 6 4 4 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Final Drive and Brakes High gear power flow ENGAGED INPUT SHAFT Iun Nk B 1c LOW SHAFT NM ai i f 3 OUTPUT SHAFT mm Low gear power flow I IE ar t 1 im 1j ENGAGED Wl cc 7 i b 1 i Neutral E E UH _ hott e a IBI H NO DOGS ENGAGED 6 15 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 02010 Polaris Sales Inc Final Drive and Brakes Input Shaft Inspection NEEDLE BEARING SNAP RING SEAL EA N Y 4 BEARING INPUT SHAFT THRUST WASHER ENGAGEMENT DOG SEROCKET LOW GEAR X SNAP RING BEARING THRUST WASHER 1 Inspect bearings to verify they roll smoothly with no tabs Verify no edge rounding exists Replace parts if flat spots engagement tabs are rounded off 2 Remove bear
22. e to the caliper bleed fitting 2 Attach the other end to a Mity Vac or similar vacuum tool 3 Bleed the system of brake fluid 4 Note the orientation of the brake line The brake line will need to be replaced in the same orientation 5 Remove the brake line from the caliper Cap or cover the end to catch any brake fluid that may still be in the line 6 Loosen the brake line from the master cylinder 1 4 to 1 2 turn 7 Remove the 4 screws that hold the master cylinder to the handlebar This will separate the master cylinder from the switch pack 168 216in Ib 18 9 24 4 N m 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc 8 Unplug the brake light switch harness from the master cylinder 6 23 Final Drive and Brakes 11 Remove the brake line from the master cylinder Install new brake line on caliper and orientate it as noted in step 4 Torque the caliper banjo bolt to 168 216 19 24 Caliper Banjo Bolt 168 216 19 24 N m N m e T 12 Insert the new brake line and install into the master cylinder Torque the brake line to 144 192 16 21 N m 1 Brake Line 144 192 16 22 N m 13 14 15 16 Tighten the brake line into the master cylinder in an orientation so that the line does not have any sharp bends when it is installed on the handlebar Route the brake light switch in the har
23. eplaced Note the orientation of the brake line before removing it 2 Remove the banjo bolt from the brake line and tie up so that all the brake fluid does not leak out 3 Ona liquid cooled caliper you will need to drain the coolant from the coolant hoses 4 Remove the two bolts 1 holding the caliper 2 to the chaincase 5 Remove the caliper from the chaincase Caliper Assembly 1 Replace caliper bolts 1 and torque them to 18 20 ft Ib 24 27 Nm T Caliper Bolts 18 20 ft lb 24 27 N m 2 Ona liquid cooled caliper hook up the coolant lines 3 Place the brake line on the caliper in the same orientation as it was before it was removed 4 Clean the threads of the banjo bolt and the threads in the caliper 5 Follow Brake Line Replacement See Brake Line Replacement on page 6 23 6 Install banjo bolt into the caliper and torque it to 168 216 in Ib 19 24 Nm 7 Bleed the brakes See Brake Fluid Replacement amp Bleeding on page 6 21 8 Ona liquid cooled caliper you will need to bleed the cooling system of any trapped air TERRAIN DOMINATION POLARIS Brake Caliper Piston and Seal Replacement NEVER RE USE PISTON SEALS ALWAYS REPLACE re PISTON SEAL CALIPER BORE PLUG PISTONS 2 DO NOT PUSH OR MOVE PISTON SEAL NN CAUTION WITH NEW PARTS DO NOT ATTEMPT TO SAND OR POLISH A CALIPER PISTON 1 Ifthe caliper is liquid co
24. ew 9 Ft lbs 12 Nm 10 Install the low gear switch Torque to specification 6 1 Low Gear Switch 21 Ft Lbs 28 Nm 11 Install the drain plug T Drain Plug 8 Ft Lbs 11 Nm 12 Fill case with 20 Ounces 600cc Polaris 80W SCL 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc Fluid DOMINAT POLARI Final Drive and Brakes Gearcase Installation 1 Tipunit onto right side Grease the driveshaft coupler and install onto end of driveshaft 2 Install the jackshaft flange and set screw bearing on the driven shaft end 3 Carefully install the gearcase unit Verify the jackshaft is inserted through the bulkhead flange hole 4 Install lower front mounting bolt 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 coupler 5 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 6 Loosensetscrews and seat driveshaft in transmission coupler stub shaft For ease of assembly make sure track has no pressure against drive shaft 7 Reattach transmission shift linkage and shift light connector Check transmission fluid level and fill if necessary 8 Install brake caliper Secure fasteners to 20
25. f you are bleeding the air repeat this step until you see only fluid coming out This may take several intervals Torque the bleeder screw to 8 11 ft lb 11 15 N m ey T Bleeder Screw 8 11 ft lb 11 15 11 12 13 When adding fluid add DOT 4 brake fluid to 1 4 5 16 6 8 cm from the reservoir top Install cover and diaphragm assembly Tighten the cover screws to 16 20 in lb 1 8 2 3 N m Cover Screws 16 20 in Ib 1 8 2 3 N m 14 15 16 6 22 Field test machine before putting into service Check for proper braking action and lever reserve Lever reserve is when the lever is firmly applied the lever reserve should be no less than 1 2 1 3 cm from the handlebar Verify that the sight glass indicates a full reservoir Check brake system for any fluid leaks Master Cylinder Lever Service COVER SCREWS r 27 PARKING BRAKE LEVER i LEVER PIN CARTRIDGE BRAKE LEVER 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc To remove the brake lever remove the E clip from the lever pin Extract the pin from the housing then remove the lever To remove the parking brake lever the housing cover must be removed Once removed carefully extract the spring noting it its position inside the housing Remove the parking brake lever To remove the cartridge completely drain the brake fluid from the housing
26. ft lbs 27Nm 9 Reinstall and secure muffler 10 Loosen rear idler bolts 11 Reinstall driven clutch and spacers onto jackshaft and tighten 12 Reinstall clutch offset washers on jackshaft and install driven clutch Using the clutch alignment tool adjust driven clutch to achieve proper offset 13 Torque driven clutch retaining bolt to specification 14 Lift 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 TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc 6 19 Final Drive and Brakes BRAKE SYSTEM Overview The Polaris snowmobile hydraulic 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 compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the pistons D located in the brake caliper move toward the disc and applies pressure to the moveable brake pads As the lever pressure is increased the brak
27. he drain plug and drain the chaincase fluid 4 Replace the chaincase drain plug and torque it to 8 ft Ib 11 N m ey T Drain Plug 8 ft Ib 11 N m 5 Remove the chaincase cover 6 Loosen the tensioner 7 Remove the lower sprocket bolt and washer 8 Shut off the fuel valve if so equipped 9 Remove the exhaust system 10 Remove the speedometer drive pickup 11 Remove the speedo drive housing 12 Remove the rear skid 13 With the sled over on its left side and the rear skid removed remove the drive shaft 14 Assemble in reverse order 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc 6 9 Final Drive and Brakes IQ WIDETRAK GEAR CASE Driveshaft and Jackshaft A S lt gt BEARING W SET SCREWS Front O 2 FLANGE ora p di C FLANGE 7 2 5 GASKET SPEED SENSOR ROTOR FLANGE z e A 35 Ft Lb 47 Nm NOTE The jackshaft cannot be removed from the gear case without gear case disassembly Lubricate the jackshaft bearing using a grease gun needle attachment 6 10 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc C POLARIS Final Drive and Brakes Gearcase Oil Level Check 1 Position the vehicle on a flat level surface 2 Position a drain pan under the gearcase Remove any Gearcase Oil dirt from the Allen head drain plug 3 Removethe drain plug with
28. ing bearing splitter and press 2 Inspect bearings to ensure they roll smoothly with no flat spots Shift Drum Inspection 3 Discard seal and spacers Replace with new parts 4 Inspect gear and spline teeth for rounded edges and or abnormal wear Replace parts as required DOWEL g 7 SHIFT INDEX ay SHIFT DRUM I WO f 0 SHIFT SHAFT 77 S M T FORK y PEWEL PIN O RING 1 Remove the detent cam spring and shaft Discard o ring and replace with new part 2 Check condition of key way and key Inspect indicator spring legs and detent areas for wear Replace parts as required 3 Shift forks can be removed from shift drum by moving shift fork to the end of it s travel and aligning with the corresponding hole in the shift drum Press dowel pins into inner shift drum Discard pins and replace with new 4 Inspect shift forks for abnormal wear and tear Replace if unevenly worn 5 Inspect shift drum tracks for damage Replace drum if any damage is found 6 When installing shift forks press dowel pins up to 100 2 5mm below top of bore Verify pins do not bottom out on shift grooves TERRAIN DOMINATION POLARIS 7 Locate spring in retainer slot as shown in illustration Arm of shift index must be positioned between both ends of spring A CAUTION Wear protective eye wear when installing spring NOTE The spring must be
29. ing 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 6 20 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 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 4 5 16 6 8 cm below lip of reservoir opening This system also incorporates a diaphragm E as part of the cover gasket and a vent port on cover 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
30. ings using a bearing splitter and press 3 Discard seals and thrust washers Replace with new parts 4 Inspect gear and input shaft teeth for rounded edges and abnormal wear Replace parts with new where applicable 5 Inspect engagement dog and sprocket engagement Low Gear Shaft Inspection 6 Inspect needle bearing cages and rollers Verify cages are not cracked and rollers are free from flat spots 7 When installing a new bearing press on or support inner race while pressing bearing onto shaft 8 Lubricate needle bearings splines with recommended gearcase lubricant THRUST WASHER ENGAGEMENT DOG GEAR BEARING SNAP RING NEEDLE BEARING THRUST WASHER SNAP RING il A gt I ZET AN BEARING THRUST WASHER 1 Press bearing from end of shaft using a press and bearing separator 2 inspect drive dogs Replace gear and mating gear if rounded chipped or broken 3 Inspect needle bearings for wear or cracks on cage 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 6 16 9922854 2007 2011 IQ Service Manual 02010 Polaris Sales Inc TERRAIN DOMINATION POLARIS Final Drive and Brakes Output Shaft Inspection SPACER SEAL BEARING SPACER N 41T GEAR BEARING 47T GEAR 1 Remove bearings us
31. ness correctly Place the switch pack with the master cylinder onto the handle bar Two smaller screws should be placed onthe top and the longest screw is placed on the lower right Follow the bleeding procedure See Brake Fluid 6 24 Replacement amp Bleeding on page 6 21 41 5 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Brake Light Switch Replacement 1 Remove the 4 screws that hold the master cylinder to the handlebar This will separate the master cylinder from the switch pack Unplug the brake light switch harness from the master cylinder 3 Unplug the brake light switch from the master cylinder 4 Replace faulty brake light switch into the master cylinder and route wires correctly 5 Plug the brake switch back into the harness 6 Replace the master cylinder to the switch pack and insert the smaller screws on the top the longest one goes into the lower right side Caliper Removal Caliper 1 Remove the two caliper bolts that hold the caliper to the chaincase 2 Remove the caliper from the brake disc TERRAIN DOMINATION POLARIS Final Drive and Brakes Caliper Replacement The only serviceable item in the brake caliper is the brake pads piston and seals If any service is required of the caliper a new caliper is available 1 The brake line will need to go in the same orientation as it was when it is r
32. oled drain the cooling system down enough to drain hoses attached to caliper or pinch inlet and outlet hoses 2 Remove the brake hose from the caliper Drain the brake fluid into a jar or suitable container 3 Rotate and remove the brake pad retaining pin and then remove the brake pads Remove the caliper from the chaincase 6 25 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Final Drive and Brakes 4 Holdthe caliper over the brake fluid jar and then push the pistons back into the caliper This will push the brake fluid in the caliper out of the brake hose banjo fitting hole 5 Clamp the end of a 1 4 thick 2 x 10 piece of steel to the workbench Allow the piece of steel to hang off of the bench by 4 5 6 Position the caliper over the steel plate with the plate firmly against one of the retracted pistons CAUTION DO NOT PUSH ON THE CALIBER BORE PLUG DOING SO WILL BREAK THE PLUG SEAL AND REQUIRE CALIPER REPLACEMENT A WARNING TO AVOID POSSIBLE INJURY DO NOT PLACE FINGERS BETWEEN PISTONS TO ATTEMPT TO CATCH THEM WHEN APPLYING COMPRESSED AIR WEAR EYE PROTECTION WHEN APPLYING COMPRESSED AIR TO CALIPER 7 Insert a rubber tipped air nozzle into the brake hose inlet port and apply compressed air to push out the piston 8 To remove the second piston lay a rubber sheet on the steel plate and position the caliper over the rubber sheet to seal the open piston bo
33. re Repeat STEP 7 9 Using aplastic or wood pick remove both piston seals from the caliper bores Discard the seals 10 Clean the caliper and pistons with denatured alcohol and dry with either compressed air or a lint free rag 11 Inspect the caliper bores and pistons for pitting heavy scoring or corrosion Replace parts if heavily scored or pitted 12 To assemble the caliper lubricate two new piston seals with new brake fluid Install each seal by inserting one point of the seal into the bore groove and then work the seal around the groove with your index finger Do not twist or rip the seals 13 Coat the piston thoroughly with new brake fluid Evenly insert each piston into the bores working each in by hand carefully and slowly Push each piston down until bottomed out 6 26 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 14 Reinstall the brake caliper on to the chaincase Torque fasteners to specification ey T Caliper Mounting Screws 18 20 ft Ib 24 27 N m 15 Inspect both brake pads prior to installation If they are within the pad wear specification reinstall into caliper 16 Install the brake hose using the same routing and orientation noted during removal Torque fitting to specification 6 1 Caliper Banjo Bolt 168 216 18 24 17 If the caliper is liquid cooled reinstall the cooling hoses Bleed the cooling system after bleeding the
34. ting with the fitting closest to the master cylinder working toward the caliper and ending with the bleed screw Always torque banjo bolts and other brake system fittings to specified torque Change fluid every 2 years or when fluid is dark or contamination is suspected Brake Fluid Replacement amp Bleeding 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 the reservoir cover Remove the two T 15 Torx screws from the cover Carefully remove the cover and diaphragm assembly from the reservoir Under the cover inspect the vent slots under the bellows and remove any debris or blockage 6 21 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 02010 Polaris Sales Inc Final Drive and Brakes 10 Bleed or replace the fluid by attaching a clear hose from the caliper bleeder fitting to a clean container Be sure the hose fits tightly on the bleeder fitting Pump the brake lever a few times and hold Slowly open the bleeder fitting and let the old fluid or air escape You will feel the lever release as you let the fluid or air escape Pump the brake lever a few times and hold it again Repeat steps 7 and 8 until you see new brake fluid coming from the caliper bleeder fitting or i
35. y 8 Lift and maneuver transmission to free drive shaft coupler 9 Maneuver transmission until it can be removed from the unit Use care not to damage coolant lines 10 Inspect transmission brakes suspension and track for excessive wear Check bearings for excessive movement or rough feeling Replace if necessary TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Inspection NOTE Gearcase disassembly assembly can be aided by positioning the gearcase on a workbench featuring a hole for the long jackshaft 1 Remove drain plug and drain transmission oil into suitable container 2 Remove snap ring spacer washer and brake disc BRAKE DISC 3 19 6 OSA XU 5 KA SNAP RING WASHER 3 Remove shift arm assembly shift detent assembly and dipstick DETENT ASSEMBLY LOW GEAR SWITCH SHIFT ARM ASSEMBLY y PA e N 2 COO yah ea f A AI WM Wr QU 9 eU yv 4 tY DIPSTICK 6 13 Final Drive and Brakes 8 Remove shift fork shaft from gear cluster Inspect fork 4 Remove case bolts for wear or bending 5 Tap cases apart with soft faced hammer in the reinforced areas NS 6 Remove the key shift index and spring Note the location of the shift index and spring for assembly 9 Removechain from input and low gear shafts Inspect gear teeth for damage Inspe
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