Once I have the drive shaft out, in what order and how do I replace the bearings that are in the chaincase and the one at the end of the jackshaft near the secondary? Do I need to remove the oil/air box (2002 XC) to do this? Do I take the brake assyembly off first, then the chain case or do the secondary bearing first? I'm not sure.

This Should help:
(1) Undo your suspension springs by un clipping them and rotating them so their is not pressure on them.
(2) Loosen your track off all the way.
(3) Undo four skid bolts mounted to your tunnel.
(4) Pull out skid.
(5) Remove secondary.
(6)Remove exhaust
(7) Remove chain case cover (After draining- there is a hole in the bottom for access)("Many would suggest not trying to remove drain plug in case. It's easily stripped, and a mess to fix") - Michahicks
(8) Remove both gears and chain. They need to be removed as a whole unit. And installed as a whole unit. When re-installing use BLUE Loctite (you can lock the brake to make this easier to undo the bolts)
(9) Remove the Speedo cable from secondary side.
(10) Remove 3 bolts that hold the housing together.
(11) You can loosen all the bolts holding the chain case to the bulkhead. And work on it on the sled. After 3 minutes you will realize it is much easier to just pull the whole chain case out. (The snap rings are a Pain to work on with the chain case still on the sled.
(12) Remove brake cable and coolant cable from the top of the chain case. (You can remove the coolant by suctioning it out of the main bottle, the down to the small plastic (T) to get the level below the chain case. It helps avoid a mess.
(13) Go to your secondary side and slide the shaft towards the chain case. You should now have enough clearance to pull it out.
(14) The bearing is pressed onto that shaft so you may need someone to remove/install it for you. Mine was not pressed on tight nor did it have a key or collar so I was able to do it myself.
(15) Check over the shaft for excessive wear on both sides. Also check out the housing for wear. Order a new Speedo Key as well. (the old one can be remove with a pick or forseps i found work good to.
(16) Now that the chain case is out. Pull BOTH snap rings out (I found I needed high quality set of snap ring pliers to do this as shit ones kept bending.
(17) Press out the bottom bearing and check it out. Do the same for the top bearing.
(18) Order new oil seals- Rubber grommet looking things with tiny springs around them.
(19) If I was you, and I am not. I would replace both the chain case bearings while it is apart.
(20) After installing your new oil seals. Push in your chain case bearings.
(21) Install snap rings
(22) Set chain case in place and (ONLY start the nuts to install the chain case, you will want some room to move when installing the shaft.
(23) Have your completed shaft put back in, Reverse removal instructions. (Be careful not to damage your oil seals. (INSURE YOU’RE TRACK IN ON THE SHAFT) Watched for a bit as my brother installed his and he had not put the track on. It was pretty funny for a few minutes.
(24) Be sure that the bearing housing backing is on the shaft before you install it. (Dont forget to install the new Key)
(25) Tighten housing some, then chain case. Then tighten both sides up.
(26) Install Gears/chain. Install hoses and lines. You can set your chain tension now also. Finger tight, and then back it off 1/8. Tighten cover-Install exhaust. You may want to get a new chain case seal. It is the black rubber around the cover.
(27) Grease EVERYTHING- You have it out so you might as well. And skid is easy to get at now cause it off.
(28) Install Speedo cable/ secondary. Skid. Tighten track back up. Bleed your brake line, Bleed coolant system if needed. And install anything else that may have been removed.
:beerchug:

Ryan Francis

Hey Tie rod.....dont order the drive shaft bearings from a polaris dealer.... If you take the old bearings with you to a John Deere dealer they can get you the same bearing for a lot less.....Part number on the bearings are even the same!!!!!!!!!!! Polaris dealer price= approx 40.00 John Deere dealer=10.00

3514525 bearing is $30US list price

make sure any replacement bearing has the same shielding over the seals, as the stock part does.

You sure your not talking about the older locking collar bearing? The new ones are pressed on, no collar.

Thanks for all the advice. I'll be ripping it apart in a few weeks. The more you know before hand helps..

Anyone know how many of each bearing is needed?
Drive Axle Clutch Side
Chain Case
Jackshaft Clutch Side
Chain Case

Only 4?

Drive Axle Clutch Side - 1
Chain Case - 1
Jackshaft Clutch Side -1
Chain Case -1

do not use any bearings except NTN BLUESIDED SEALED RACING BEARINGS.....you'll thank me later on...cost more but last 10,000 miles with no greasin :div20:

No worries already had that planned. Picking them up at the royal distributing sale this weekend

Don't want to jack the thread but anything else I should replace while I have everything apart?

Oil seals/ o-rings, clutch ramps, skid bearings, shock rebuild, chaincase gasket, inspect gears/ chain. hyfax.

^ and synthetic gear oil