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How do I take my chaincase off? ( 91 Indy 400)

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  #1  
Old 11-29-2007
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Default How do I take my chaincase off? ( 91 Indy 400)

I've got everything loosened up, but the jackshaft bearing won't budge? How do I get this chaincase off. I already screwed up this project once by forgetting to take the snapring off of the driveshaft bearing and pounding it with a hammer from inside the tunnel. After a lot of pounding, the groove in the chaincase that held the snapring shattered, and now I imagine I have to replace the chaincase. I guess that's what I get for starting a project last April, and not looking at it again until today.
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  #2  
Old 12-02-2007
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If this helps go to the Polaris dealer and see if they can pull up a parts picture of the chaincase and get a print out from them. It should show all the parts that you would need to remove. A picture would help also of your chaincase for us visual people.
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  #3  
Old 12-02-2007
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Here's a 94 Indy Classic chaincase:

http://www.partsland.com/index.cgi?N...NCASE-ASSEMBLY

And here's a 95 Trail case:

http://www.partsland.com/index.cgi?N...NCASE-ASSEMBLY

And drivtrain:

http://www.partsland.com/index.cgi?N...TRAIN-ASSEMBLY

Not sure how much those will help, I can't imagine too many differences. I am not familiar with that exact chaincase, only the older stuff and the newer stuff. The_Hog might give a little more insight.
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  #4  
Old 12-02-2007
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Getting the chaincase off the jackshaft can be a bugger. What I do to help is take the bearing off on the speedo side of the driveshaft and yank on it and get it broke lose from the chaincase, then take the bearing flange off on the clutch side of the jackshaft and take a peice of wood and a hammer and hit on it to get it to move. Once you get it to move then it is usually alittle easier to get the chaincase off. Sorry if its hard to understand, I am horrible at explaining things.
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  #5  
Old 12-03-2007
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Will the bearing be stuck to the chaincase, or the jackshaft? I already have the driveshaft and the bottom bearing out.
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  #6  
Old 12-03-2007
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Quote:
Originally Posted by Ibreakstuff View Post
Here's a 94 Indy Classic chaincase:

http://www.partsland.com/index.cgi?N...NCASE-ASSEMBLY

And here's a 95 Trail case:

http://www.partsland.com/index.cgi?N...NCASE-ASSEMBLY

And drivtrain:

http://www.partsland.com/index.cgi?N...TRAIN-ASSEMBLY

Not sure how much those will help, I can't imagine too many differences. I am not familiar with that exact chaincase, only the older stuff and the newer stuff. The_Hog might give a little more insight.
WHOOOAAAA! I clicked on that first link and I almost shit myself with confusion! I've got a big bucket of parts that I don't know where they go, but not THAT many. That must have reverse or something, or else I've got to start digging around in the garage and looking for ALOT more parts.
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  #7  
Old 12-03-2007
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You can take the chaincase off without removing the bearings out of it. I always do.
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  #8  
Old 12-03-2007
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Here's my understanding of the situation. If I take the driven clutch off, there will be a flange holding the jackshaft bearing on the pto side. If I take that flange off, I can tap on the mag side of the jackshaft and it should come off?


How do I put it back on then. I need to put another chaincase in, so I'll have to remove the jackshaft bearing.
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  #9  
Old 12-03-2007
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Yep three bolts on the pto side jackshaft flange and then the bearing will float free. Make sure when you tap on the jack shaft on the mag side to use a peice of wood and not hit it directly with a hammer. Once you get it to move alittle then it makes it easier to pull off. Its a bitch and you have to wrestle with it, but it should come off.

Remove the jackshaft bearing out of the chaincase?
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  #10  
Old 12-03-2007
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I figured it must be stuck in there pretty hard, otherwise the bearing would stay on the shaft as I pulled the chaincase off. Is there a snapring on the back side of the chaincase too?
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  #11  
Old 12-03-2007
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Have you removed the bearing carrier half from the inside of the case?
Bearing should come out the same as the lower on on the drive shaft, to the inside of the case.
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  #12  
Old 12-03-2007
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^^^^^Ummmm I had some "problems" removing the lower bearing. I hadn't looked at this project since last April and I had the sled flipped over the other day. I saw the outer race of the driveshaft bearing was stuck so I decided a hammer and chisel was in order. I was pretty proud of myself until I flipped the sled over and saw the snapring and a bunch of cracked aluminum in the bellypan. I guess I don't really see anything on there that I'd call a bearing carrier half, but I haven't been out there working on it, so I'll wait to update you guys when I've done more work.

It might be awhile before I do more work because they're calling for 3 to 5 inches of snow tomorrow and I'd rather ride than wrench. The official total we got here was 10.3 inches. If we added 5" to that tomorrow, the riding conditions would be pretty good.

Thanks for the help guys.
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  #13  
Old 12-03-2007
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There are a few things that would be helpfull to know about your current situation.. First of all doing all of this is 100 times easier if you take the airbox out... Second of all you say you loosened everything up...

Do you mean just on the chain case side or the clutch side as well I would assume you took the cover off the drive shaft so the carriers for the bearings where loose and out of the way... Also on the jackshaft the 3 bolts the hog described on the jackshaft need to come all the way out... just loosening them wont do much. next to take the case off you have to have the gears, chain ect all off...

There are snap rings that hold the one shaft in place.. but since you said that you busted that already id check to be sure that all of it came out... pieces or a piece may be wedged in there and you might no know it.. That would make it very hard to get out.. Also if things of this nature pound out hard then somethings wrong... Its ok for it to be a little hard but if you have to pound for more than a couple minutes strain and exert a great deal of effort.. you have a problem, usually pounding harder isnt the answer.

Next I assume you know that there are bolts that hold the chain case on... Most of these dont come out very easy unless you take out the airbox and in some cases the brake caliper as well..

As for that diagram for the 94, yes that is with reverse... Dont even bother to look at that everything down to the Case is 100 percent differnt than what you have.. That wont help you at all..

I have a diagram at home that Ill post for you at 6:30 tonite... Hopefully then you will get a better understanding of what you have.

Last edited by TwentySIXRed : 12-03-2007 at 01:06 PM.
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  #14  
Old 12-03-2007
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Default Chain Case specs 91 Indy 400

First of all there are 2 different chain case and brake configurations for this sled... You have to figure out which one you have....

The first ones number is 1802329, the second 1802330. There are differences between the two.. Make sure of which one you have...

Also I know the pics are small you can save them and view them in a differnt window to rezise them so you can see them clearer... I have the part numbers for all the stuff as well from 08 to 1985... These are oem parts....
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Last edited by TwentySIXRed : 12-03-2007 at 07:06 PM.
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  #15  
Old 12-10-2007
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You probably already have it apart but the jackshaft and chaincase come out as one unit. The jackshaft is pressed into the top bearing in the chaincase. You will have to remove all the brake assembly to remove the case. If you are replacing all the bearings take a dremal and cut the race of the bearing on the clutch side. It will make removing that bearing much easier. If you have to pound on things with a hammer your not doing it right.
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  #16  
Old 12-10-2007
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I'm working on it right now, and I'm majorly pissed off. My next step is to cut the bearing off of the clutch side. I'm sorry guys, but I've done A LOT of pounding already with no results. I've probably wrecked other stuff that I'm not aware of. I guess I'm just a shitty mechanic. I'm also going to try to figure out how to take off the brake caliper assembly. Initially it looked like it wouldn't come off before the chaincase came off, but maybe I'm wrong.

Also, a guy on SF has a chaincase from an 88 or 89 Indy Trail. Will this work on my sled.

Thanks

Last edited by Rubi : 12-10-2007 at 04:36 PM. Reason: adding
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  #17  
Old 12-10-2007
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Yeah, the chaincase is off now. I kind of mushroomed the end of the jackshaft, but I filed out the splines, and I can get the sprocket on pretty easily now. I had to cut the bearing off the pto side, and then take off the oil and coolant tanks to get the chaincase and shaft out. Then I had to cut the bearing off the chaincase side too. What a royal pain in the ass! Any hints at what order to reassemble things would be appreciated.
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  #18  
Old 12-10-2007
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Yes this is definately not a "reverse of how you took it apart" scenario...
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  #19  
Old 12-11-2007
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Rudy if you need a new jackshaft I have one you can have for the cost of shipping.
The jackshaft is definitly press into the bearing and pounding the hell out of things causes bigger problems.
Riley
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  #20  
Old 12-12-2007
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Thanks for the offer Riley. I might have made the hammering I did sound worse than it actually was. I just cleaned up the ends of the splines with a triangular file, and it seems to be alright now. I'm a little more worried about the driveshaft at this point. There is some wear on the shaft where the chaincase bearing rides. My buddy rode it home after the bearing siezed which wasn't good. I'll maybe post a picture of the driveshaft so you people in the know can tell me whether I need to replace it. I'm getting sick of spending money on a sled that I keep for my friends to ride!
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