1990 Polaris Indy - I Cant get the chain case off!

3834 Views 8 Replies 7 Participants Last post by kccats, 5 mo ago

kjackson7710

Discussion Starter · Jan 14, 2011

I have a 1990 Polaris Indy 500 that I am having a hell of a time getting the Chain Case off to change the Brake Disc Rotor. I have loosend the brake caliper free from the chaincase housing, took off cover, removed both gears & chain, removed the 3 bolts that hold the chaincase onto the frame/tunnel… I have pushed, pulled, pry'd that SOB in every direction the lower shaft seems to have broken free but the top shaft seems like it is locked on tight! Any suggestions? Is this just a case of having of using elbow grease? which I have been doing the most I thought I could without breaking something… Is this case supposed to just slide off after I have taken the bolts/gears/chain and everyhting off? no need to remove snap ring, bearings or anything? Im ready to set this thing on fire- seriously.

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jKsled

· #2 · Jan 14, 2011

the bearings are housed inside the case, they might be frozen to the shaft. when you pull the chaincase out the bearings come with it.. if you're positive you have all bolts off and anything that might be holding it on, then that is probably the case. try to keep the case aligned with both top and bottom, don't take one side off too far or it will get misaligned and the axles wont slide easily out of the bearings.
If this happens to me I usually take a rubber mallet and pound on the end of the shaft that is giving me trouble, while holding a long screwdriver or skinny prybar behind the chaincase, trying to pry it out as i pound the shaft.

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SledHead454

· #3 · Jan 14, 2011

jKsled said:
If this happens to me I usually take a rubber mallet and pound on the end of the shaft that is giving me trouble, while holding a long screwdriver or skinny prybar behind the chaincase, trying to pry it out as i pound the shaft.

:thumbsup:

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kjackson7710

Discussion Starter · #4 · Jan 14, 2011

Thanks for the Tip I will give it a shot with the rubber mallet... They have to be frozen to the shaft and thats kinda what i was thinking but i didnt want to pry to hard without knowing if there was anything else that needed to come out. Thanks for advice i will give it hell tonight and let you know how it goes.

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SledHead454

· #5 · Jan 14, 2011

kjackson7710 said:
Thanks for advice i will give it hell tonight and let you know how it goes.

:laugh: good luck!

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indy_steve

· #6 · Jan 16, 2011

just be careful. i snapped the back side of my case out ware the brg seatsand the seal resides. wound up repacing everything. alough i did convert to reverse while i was at it but just be careful or it could bite u in the ass

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Indy_lover

· #7 · 5 mo ago

kjackson7710 said:
I have a 1990 Polaris Indy 500 that I am having a hell of a time getting the Chain Case off to change the Brake Disc Rotor. I have loosend the brake caliper free from the chaincase housing, took off cover, removed both gears & chain, removed the 3 bolts that hold the chaincase onto the frame/tunnel… I have pushed, pulled, pry'd that SOB in every direction the lower shaft seems to have broken free but the top shaft seems like it is locked on tight! Any suggestions? Is this just a case of having of using elbow grease? which I have been doing the most I thought I could without breaking something… Is this case supposed to just slide off after I have taken the bolts/gears/chain and everyhting off? no need to remove snap ring, bearings or anything? Im ready to set this thing on fire- seriously.

I have this same problem but I have to remove mine because the previous owner has removed a rather large chunk off the top of the chain case and I now need to replace the whole thing... I will attempt the method that SledHead454 had suggested and work my way through from there.

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Indy Joe

· #8 · 5 mo ago

I’ve taken multiple chaincases off 90-99 indy’s and its probably one of the worst things to remove off these chassis. One big crow bar to the back and move from one side to the other. Only 3 bolts holding it to the chassis. If those are off, its just the bearing seized or really tight on the shaft. Alot of elbow grease and possibly some swearing. Lol have fun.

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kccats

· #9 · 5 mo ago

Get a large gear puller
Push the shaft out

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