How To Install the Power Module Gear Set For the Polaris ATV Cleaner

WRITTEN BY:  Inyo Pools

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If your Polaris ATV Suction Cleaner wheels are locked up or rotate freely without moving your Cleaner, you may have one or more damaged gears in the Power Module of your Polaris ATV Suction Cleaner. This guide shows you how to replace the gear set in your Cleaner. Note: This guide assumes that you have removed the Power Module out of the Cleaner. See our guide on How To Replace the Power Module on a Polaris ATV Suction Cleaner before starting this guide.

Step by Step

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Step 1

ORDER PARTS - The first step is to order the parts you will need. The only part you will require for this procedure is the Polaris ATV Suction Cleaner POWER MODULE GEAR SET. It contains a set of 10 gears. This guide only covers the replacement of 8 of these gears excluding the two circled. These two gears are embedded in another section of the Power Module and generally do not fail.

Step 2

GEAR SET - This is a picture of the gears being replaced. The number displayed with each gear is stamped into the surface of the gear.

Step 3

UNFASTEN BACK PLATE - Remove the 4 screws that secure the Back Plate to the Power Module.

Step 4

LIFT OFF BACK PLATE - Lift the Back Plate off of the Power Module to expose the Turbine Paddle.

Step 5

REMOVE TURBINE PADDLE - Remove the single screw that holds the Turbine Paddle onto its shaft. Lift off the Turbine Paddle. This will free up the end of the Turbine Paddle shaft so that its gear #1 can be removed from the other end.

Step 6

UNFASTEN TRANSMISSION COVER - Remove the 3 screws that secure the Transmission Cover to the Power Module.

Step 7

LIFT OFF TRANSMISSION COVER - Lift the Transmission Cover off of the Power Module to gain access to the Power Module Gears.

Step 8

LIFT OFF BEARING SUPPORT - Remove the Bearing Support to gain access to Gears #1 and #2.

Step 9

VIEW GEAR SET - This picture (rotated 180 degrees from the previous picture) shows the placement of 7 of the 8 Gears to be replaced. The 8th Gear is incorporated in the Gear 2 Assembly.

Step 10

LIFT OFF GEAR 7 - Remove Gear #7 to uncover the Worm Gear, #5. Note: the number of each Gear is stamped into the upper side of each Gear.

Step 11

ROTATE GEAR 5 - Rotate Gear #5 counter-clockwise to release it from the gear well.

Step 12

LIFT OUT GEAR 5 - Lift up Gear #5 to remove the Gear from the Power Module. If the Gear does not lift out, rotate it counter-clockwise again.

Step 13

FLIP TIMER CROSS SHAFT - Sometimes this Gear breaks off inside the gear well. Put your hand over the rest of the gears and turn the Power Module over. Flip the Timer Cross Shaft a couple of time to free the broken pieces. They should drop out.

Step 14

REMOVE MIDDLE GEARS - Lift off Gears #6, #4 and #3. Then pull the #2 Gear Assembly out of its well.

Step 15

REMOVE GEAR ASSEMBLY 1 - Remove Gear Assembly #1 from its well. This is the gear that was connected to the Turbine Paddle.

Step 16

REMOVE GEAR 1 BEARING - To replace the gears that are incorporated in the two Gear Assemblies, you will have to disassemble the Gear Assemblies. For the Gear #1 Assembly start by removing the Gear #1 Bearing. It is held on with a single screw.

Step 17

PULL GEAR 1 OFF SHAFT - Next slide Gear #1 off of its shaft. I used a rubber lid opener to hold the gear while sliding it off.

Step 18

REMOVE TOP BEARING ON GEAR 2 ASSEMBLY - Move to Gear Assembly #2 and unscrew the top bearing.

Step 19

DISMANTLE REST OF GEAR 2 ASSEMBLY - Next dismantle the rest of the Assembly by unscrewing the bottom gear (#8) and bottom bearing, and sliding Gear #2 off its shaft.

Step 20

REASSEMBLE GEAR 1 ASSEMBLY - Put the #1 Gear Assembly back together using the new Gear #1. Look at the picture to make sure the gear is placed onto the shaft correctly. And make sure the Gear is pushed up all the way to the bottom of the bearing.

Step 21

REPLACE GEAR 1 ASSEMBLY - Drop Gear Assembly #1 back into its well.

Step 22

REASSEMBLY GEAR 2 ASSEMBLY - Reassembly the Gear #2 Assembly as shown using the new Gear #2.

Step 23

REPLACE GEAR 2 ASSEMBLY - Drop Gear #2 Assembly into its well. Wiggle it a little to make sure it engages with the lower Gear at the bottom of the well.

Step 24

CHECK PLACEMENT OF GEAR 2 -It the Gear #2 Assembly is not fully engaged, it will sit too high. Check that the bearings for Gear Assemblies #1 and #2 are level - that #2 is not higher that #1.

Step 25

REPLACE MIDDLE GEARS - Place new Gears #3, #4, and #6 onto the Power Module in ascending order. Note: the gear positions are stamped into the Power Module. When you replace these gears, MAKE SURE THE NUMBERED SIDE IS FACING UP.

Step 26

REPLACE GEAR 5 - Place the new #5 Gear into its well and rotate it clockwise to engage it with the gear below.

Step 27

REPLACE GEARS 6 AND 7 - Place the new #6 and #7 Gears onto their respective posts - #6 first - NUMBERED SIDE UP.

Step 28

REPLACE BEARING SUPPORT - Replace the Bearing Support on top of the Gear #1 and Gear #2 Assemblies.

Step 29

REPLACE TRANSMISSION COVER - Replace the Transmission Cover back onto the front end of the Power Module. The two slots on the outside of the Transmission Cover have to engage with the tabs coming off of the two blue Engagement Cogs. See picture. Also, If you find that the Cover does not close completely, check the placement of the Gears. I had two gears riding too high because I'd placed them upside down with their numbers down. Don't force this cover. If it doesn't close snugly, recheck everything before you screw it down.

Step 30

SECURE TRANSMISSION COVER - Fasten the Transmission Cover down with its 3 screws.

Step 31

REPLACE TURBINE PADDLE - Place the Turbine Paddle on its shaft and secure it with its screw.

Step 32

REPLACE BACK PLATE - Replace and fasten the Back Plate down with 4 screws.

Step 33

TEST POWER MODULE - Using a screwdriver, MANUALLY rotate the right Reverse Drive Mechanism clockwise to ensure that: it moves without binding; the Propeller shaft rotates and the white Timer Cam moves counter-clockwise.

Step 34

REPLACE POWER MODULE - Go back to our guide on How To Replace the Power Module on a Polaris ATV Suction Cleaner to re-install the Power Module.

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Anonymous  Posted: 09/05/2016 18:15 PM 

Very Helpful. I just saved hundreds of $$$ with this step-by-step easy-to-follow instructions. God bless you!