Indy XLT issue

Post by **Matt** » Sat Feb 02, 2008 3:52 pm

1995 Polaris Indy XLT - Last weekend when riding, the drive shaft bearing on the speedometer drive side failed - it blew apart. So now I am trying to remove the drive shaft, but it won't budge. There is nothing left on the speedometer drive side, and it doesn't look like there is anything else retaining it on the chain case side (I removed the lower sprocket). I can't really get a good hit on it anywhere with a soft hammer, and I'm afraid I will break a drive sprocket if I put too much force on with a pry bar.

Any suggestions?

JDT · Post by **JDT** » Sun Feb 03, 2008 3:50 am

Isn't there a locking bearing on the drive side behind the sprocket?

Is there a retainer plate visable from under the tunnel?

Post by **Matt** » Sun Feb 03, 2008 5:10 pm

Under the sproket, there is a snap-ring (which I tried to remove but the arms on my snap-ring tool aren't long enough) and then the bearing. As far as I can see, the shaft should slide out of that bearing. I have a tech manual but it doesen't say anything else is here. There is no retainer on that side underneath, only on the speedo drive side.

JDT · Post by **JDT** » Sun Feb 03, 2008 5:29 pm

Sounds like a new tool will be in you toolbox soon.
Years ago I bought a set of eight snap-ring pliers. Several sizes and jaws that are straight, 45 and 90 degress.
Expensive for something you don't use often but when you need it you need it.

dodger · Post by **dodger** » Mon Feb 04, 2008 6:03 pm

Matt,
I have ground down the tips of some cheap long nose needle nose plyers and use them to remove that bearing retaining snap ring(put a backgrind on them so the catch good). A word of advise is be very carefull that you dont pinch your palm if it should slip out.(major blood blister)
With the old drive sprokets that have 4 cogs sometimes the easiest thing to do is remove the 3 bolts that hold the chaincase to the chassis. With the snap ring and the bearing out you should be able to push the drive shaft toward the chaincase and remove the shaft. The coolant hoses can be a bear to deal with but I have seen times that that is the only way to get the shaft out.
Now that Polaris has went with 2 and 3 cog drivers the job is much less stressfull.

Deleted User · Post by **Deleted User** » Wed Feb 06, 2008 9:25 am

There are 2 ways to remove shaft

1) remove lower brg from chain case this will let shaft move to right more ( you have a 4 drive system )

2) the better way remove chaincase from tunnel replace brgs and seal in chain case and speedo side. while you are there replace the brg behind the driven clutch

Liquifire 4/6 · Post by **Liquifire 4/6** » Wed Feb 06, 2008 11:09 am

Matt, just wondering if prior to the LH drive shaft bearing packing it in, did your speedometer quit working? This doesn't happen every time a bearing begins to fail, but more often than not as the bearing starts to go bad, the short speedo angle drive core will break because it goes out of line with the shaft center. Just thought I'd mention this because I've seen many drive shafts seriously damaged from running too long with a bad bearing. If your speedo quits, check the speedo core and if it's broken, closely inspect the bearing and you may find it is in need of replacement. It can save you alot of grief and expense if you catch it before your shaft starts to wear.

Post by **Matt** » Wed Feb 06, 2008 9:30 pm

Pete,
I wish I knew that about 2 seasons ago when the speedometer quit working. Never bothered to figure out why. Someone else asked me the same thing, because it happened to him too.

Thank you all for the advice. I need to find time to work on it now.

Post by **Matt** » Thu Feb 07, 2008 9:55 am

Rich,
Unfortunately I'm not coming west this time. Anyway I would be worried about riding a "new" XLT, since it sounds like so many of them had crank failures with less then 3k miles. Maybe they fixed that problem by '96?

Post by **Matt** » Thu Feb 07, 2008 9:24 pm

There is a topic on vs.com right now about mid-90s XCRs - there seems to be a lot of interest in this "vintage" already. Of course there are so many XLTs in circulation they'll probably never be worth much, kind of like the JD 400.

Post by **Matt** » Mon Feb 11, 2008 9:32 am

I finally got to work on it again, 2 hours later it is apart.

Does anyone happen to have a chaincase for this? The lip that retains the snap ring on the lower bearing is half torn off. It looks like when it broke, and I limped it back, the driveshaft was on an angle, so it forced the bearing to twist against the snap-ring and damaged the housing.