Chain and Gear Replacement HELP!

[salomon]

So I am looking to replace my chain and gears. I have never opened up my chain case before. I am not looking for a tutorial but Is there anything I should look out for? Can I just open it up? Should I tip the sled on its side? Is it as simple as opening it up taking gears and chain out and replacing? any special tools needed? I have limited experience but am trying to gain as much knowledge as possible. Sled is 05 Rev adrenaline 159.

Anything will help.

Thanks!

 

[Waterdawg]

I just did this for the 1st time last week. Same sled as yours. Drain all the chaincase oil out of your sled. There is a drain plug. Take the 4 bolts out of the chaincase cover. Now take the pin out of your adjuster and loosen up the adjuster bolt all the way.Your tensioner will then slide out. The top gear has a cotter pin. take this out and the nut should be fairly loose. Like the nut holding a wheel bearing.The bottom gear takes I think a 15 mm wrench. Pay attention what side is out.When you put it all back together use some blue locktite on the bolt for the bottom gear and torque to 35 ftlbs. Tighten up your chain by hand and insert pin.I used synthetic atf. Much cheaper than the doo lube. Good luck.

 

[enis750]

I just did this for the 1st time last week. Same sled as yours. Drain all the chaincase oil out of your sled. There is a drain plug. Take the 4 bolts out of the chaincase cover. Now take the pin out of your adjuster and loosen up the adjuster bolt all the way.Your tensioner will then slide out. The top gear has a cotter pin. take this out and the nut should be fairly loose. Like the nut holding a wheel bearing.The bottom gear takes I think a 15 mm wrench. Pay attention what side is out.When you put it all back together use some blue locktite on the bolt for the bottom gear and torque to 35 ftlbs. Tighten up your chain by hand and insert pin.I used synthetic atf. Much cheaper than the doo lube. Good luck.

very good advice
I will add a few pointers for you

when taking out the gears, take the gears (top and bottom) and the chain out all at once
repeat when putting back in too, put it all together on your CLEAN workbench and place it back it
you may have to play with the placement of the gears to get them to fit proper, but its a SUPER easy job bro

also, 35 ft.lbs of torque on the lower gear bolt - again, do not over tighten

when tightening your tension, HAND TIGHT only
just get it tight, then back it off enough to fit the cotter pin back in
do not over tighten it and force the cotter pin back in
check it every ride, as the chain will losen up and become loose again

other than that, have some beers and get at er!

have fun!

 

[mastertech]

That pretty much sums her up!!

 

[HuskyPower]

how much fluid are you guys putting in? just fill 'er up till it hit the dipstick or is there an acutal specific amount?
thanks

 

[jd1964]

I think it is around 10 oz .

 

[enis750]

8 oz.
I just fill through the dipstick hole and watch till it hits....but it is 8 oz.

 

[salomon]

thanks for all the help!

so I did everything you guys have talked about but my bottom gear...not so easy to remove...?

My other question is, what justifies new gears and a chain. My sled has about 2000miles on it and it really didnt look like the oil had been done before.

I just want to make sure that I do it right the first time! But my main concern is the bottom cog, as that is really not coming off.

Thanks again! you guys rule!

 

[enis750]

thanks for all the help!

so I did everything you guys have talked about but my bottom gear...not so easy to remove...?

My other question is, what justifies new gears and a chain. My sled has about 2000miles on it and it really didnt look like the oil had been done before.

I just want to make sure that I do it right the first time! But my main concern is the bottom cog, as that is really not coming off.

Thanks again! you guys rule!

once you remove the bolt on the bottom gear, it should just come off
you have to pull it off w the top gear and chain sorta all at once
maybe its binding on the shaft a little as you pull it out - this may cause it to sorta be difficult to pull off (because it;s not coming off perfectly straight)

06's were prone for chains breaking, 05's were ok i think
its a cheap way to ensure peace of mind
I would do the chain if ur already in there, but if you inspect the gears and they seem ok, just leave em

unless you are regearing....obviously

 

[28shooter]

I just did this for the 1st time last week. Same sled as yours. Drain all the chaincase oil out of your sled. There is a drain plug. Take the 4 bolts out of the chaincase cover. Now take the pin out of your adjuster and loosen up the adjuster bolt all the way.Your tensioner will then slide out. The top gear has a cotter pin. take this out and the nut should be fairly loose. Like the nut holding a wheel bearing.The bottom gear takes I think a 15 mm wrench. Pay attention what side is out.When you put it all back together use some blue locktite on the bolt for the bottom gear and torque to 35 ftlbs. Tighten up your chain by hand and insert pin.I used synthetic atf. Much cheaper than the doo lube. Good luck.

were is the drain plug located at. can you see it or is it under the chain case?

 

[mastertech]

ITs just simple to take the cover off and let it drain that way.. easier..

 

[mastertech]

p.s.. Go with ski-doo lube.. nothing but!!

 

[Dog-Man]

p.s.. Go with ski-doo lube.. nothing but!!

Doo lube, last I checked was like 20 bucks for a rather small container. I have been using cheap CTC synthetic 75w90 for many many moons. About 12 bucks for a litre....does many chaincase oil changes....