Step 1

If your sled has a Drain plug for the chain case, remove it and drain oil into a suitable container. On Polaris models you will need a 3/16” allen wrench to remove the plug. The plug is located directly below the chain case underneath the snowmobile.
Step 2



Now release the tension on the chain by backing off the jam nut and loosening the tension bolt highlighted in green.
Step 3



Once the oil is drained, remove the 4 bolts Highlighted in Green in the above picture. Now that the bolts are removed, the cover should come off without much effort. Take care when removing the cover not
to damage the rubber seal.
Step 4



To remove one gear you will need to remove both the top and bottom sprocket and the chain. On the Jackshaft (top sprocket) you will first need to remove the cotter pin before you can loosen the nut as seen in the above picture.
Step 5



Now loosen both the top and bottom sprocket retaining bolts and remove them. Once these retaining bolts are out, pull the top and bottom sprockets off of their respective shafts simultaneously.



View of empty chaincase

Note: When purchasing your new gear be sure to ask your dealer if you will need a chain of a different length.



The sprocket and chain assembly removed from the chain case pictured above
Step 6

To reinstall the new sprocket(s) and/or chain, you must put the sprockets inside the chain as in the above picture and slide each sprocket onto its shaft at the same time.
Step 7

Now reinstall the bolts and tighten them to the mfg’s torque specs.
Step 8

Now that the bolts are torqued down lay a straight edge across the gears to assure that they are lined up with one another. If one gear is too far in, shim that gear out. Shims are available from your dealer.
Step 9

If gears are aligned properly reinstall the cover, rubber gasket and the 4 retaining bolts.
Step 10

Set Chain tension according to your owners manual. Once the chain is tensioned, don’t forget to tighten the Jam nut on the tensioner bolt.
Step 11

Reinstall Chain case oil plug if you haven’t already
Step 12

Remove chain case dipstick or filler plug depending upon your model and fill the chain case with oil. As a guideline most chain cases use around 8 ounces of oil, but each particular sled is different. Check the oil level on the dipstick to be certain of when its full.

Written by: TriumphoverU