2004 Polaris Touring Service Manual, Page 276Get this manual
BRAKESFINAL DRIVE Wide Trak Transmission Removal
1Hood can be removed to prevent damageMark hood hinges for ease of alignment when reassembling unit2Remove battery3Turn off fuel valveMove oil tank for access4Remove air intake and coolant recovery bottle from its mountingdo not remove entirely)5Remove drive belt6Remove driven clutch retaining bolt assembly and drive clutchNote number of spacers which are behind driven clutch for installation during reassembly procedures7Remove muffler springs and muffler from unit8Loosen brake cable jam nut (A) and remove cable bolt, nut and spacer (B)Use care not to lose spacer9Remove cable from transmission10Note location of shift linkage on transmission to assure proper location during reassemblyRemove cotter pin, washers, and pin from transmission arm11Remove brake light wire connector from sensor12Loosen rear idler wheels and bolts13Loosen jam nuts on adjustment bolts on both sidesBack out adjustment bolts to allow rear idler assembly to come forward, relieving track tension14Tighten idler wheel bolts so that spacers on shafts do not rotate and lose alignment15Remove front and rear carrier shaft bolts (A), and front and rear suspension bolts from both sides16Place protective mat on the floorTip unit onto right side and remove suspension17Remove (2) bolts, nuts, and flangettes supporting jackshaft bearingLoosen and slide back lock ring from transmission end of jackshaft18Remove jackshaft by pulling towards driven clutch side and lifting upward through bulkheadIt may be necessary to lightly tap on bearing collar to free coupler of jackshaft from transmission end19Inspect bearingIf loose on the shaft the shaft must be replacedIf bearing is rough when turned, the bearing must be replacedThe bearing is pressed onto the shaft and will require puller for removalB A