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Step 5: Next, you'll need to remove the body side panels and the belt guard. Then use Ski-Doo's clutch deflection tool to loosen the deflector bolt. Once the clutch faces are separated far enough, the belt simply slips over the sheaves. Note that to make it easier to reach the clutch, we popped off the airbox straps and removed the airbox as well. Then, remove the clutch retaining bolt along with the jackshaft bearing retaining shell. Remember, the QRS is a one-piece unit, so a number of parts must be removed before the jackshaft/clutch assembly can be removed.
Step 6: Move to the other side of the sled and remove the chaincase breather to gain access to the top gear in the chaincase. Loosen the upper gear retaining bolt. When removing the bolt and washer, thread in the upper gear retaining tool (part no. 529 036 110, about $42). The tool functions as a slide hammer with its outer sleeve so you can keep the upper gear in position and use the retaining tool to tap the gear until the jackshaft separates from the gear. This is a much easier way to address the jackshaft, but you can also remove the top gear by disassembling the entire chaincase. This will allow you to remove the jackshaft, but you also must remove the pipe, muffler, chaincase cover, chain, and upper gear. We recommend investing in the retaining tool as it will save you considerable time.