2004 Polaris Touring Service Manual, Page 277Get this manual
BRAKESFINAL DRIVE 20Loosen and remove three carriage bolts and nuts retaining angle drive housing and flangettes21Remove angle drive housing, adaptor key, flangettes, gasket, and bearing from drive shaft and tunnelNOTE: It is not necessary to remove speedometer cable from angle driveReplace adaptor key any time drive train assembly is serviced22Tip machine back onto floor23Remove right side bumper plug (A)24Remove bolt retaining rear of bumper to foot rest25Bend muffler mount out of the way to allow transmission removal26Remove three transmission retaining boltsNote all alignment shim quantities and locations for reassemblyNOTE: Retaining bolts have to be held in place from underside while removing nutsThe lower front bolt cannot be removed at this timeIt must be lowered to the drive sprocket27Lift and maneuver transmission to free drive shaft coupler28Lower drive shaft and remove lower front bolt29Maneuver transmission until it can be removed from the unitUse care not to damage coolant lines30With transmission removed, tip unit onto right sideNotice direction of track rotation for reassemblyThe arrow in the photo at right indicates track bottom, rear of unit31Remove front and rear carrier shafts 32Remove suspension by pulling rear of track out of tunnelSlide suspension forward to driveshaftLift up and out at the rearNOTE: On some models it may be necessary to unhook rear torque arm springs to allow torque arm to lower33Inspect transmission, brakes, suspension and track for excessive wearCheck bearings for excessive movement or rough feelingReplace if necessaryDirection of Rotation