Polaris 3900 Repair Manual

3900 Sport Tear Down Instructions

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TABLE OF CONTENTS DISASSEMBLY BAG SWEEP HOSE REMOVAL ..................................................................... 4 BOTTOM HOUSING REMOVAL ................................................................... 5 WATER MANAGEMENT REMOVAL ............................................................. 6 WHEEL REMOVAL ......................................................................................... 7 GEAR BOX ASSEMBLY ................................................................................ 8 TOP ASSEMBLY ............................................................................................ 9 DRIVE TRAIN .................................................................................................. 10-14 PRODUCT BREAKDOWN ........................................................................................ 15 COMPONENT PARTS .............................................................................................. 16 ASSEMBLY AXLE ASSEMBLY .......................................................................................... 17 GEAR BOX ...................................................................................................... 18 WHEELS & CHAIN.......................................................................................... 19-21 TOP ASSEMBLY ............................................................................................ 22 WATER MANAGEMENT ................................................................................ 23 BOTTOM & SWEEP HOSE ........................................................................... 24 BAG & QUICK DISCONNECT ....................................................................... 25

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BAG AND SWEEP HOSE REMOVAL Press logo buttons to remove Quick Disconnect

Remove bag by twisting collar

Remove Sweep hose by twisting nut to release from hose

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BOTTOM HOUSING REMOVAL Remove 3 screws from bottom of cleaner

Remove Bottom Housing

Locate 3 screws labeled “A” and remove.

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GEAR BOX REMOVAL Remove Water management System and Rear Housing

Locate 4 screws labeled “B” and remove

Remove Gearbox and single side wheel

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GEAR BOX REMOVAL Pry hubcap with flat-blade screwdriver for removal

Un-thread screw to remove wheel

Pull wheel from gearbox shaft

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GEAR BOX COMPONENTS Gearbox Assembly Part #39-200

Notes:

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TOP ASSEMBLY REMOVAL Locate and remove 2 screws in order to remove the Top.

Remove Top

Top Assembly Part #39-003, includes float.

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DRIVE TRAIN REMOVAL Pry hubcap off double-side wheels with flat-blade screw driver

Un-thread screw to remove wheel.

Remove wheel.

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DRIVE TRAIN REMOVAL Remove wheel sprocket cover to expose chain

Remove chain from rear wheel sprocket

Remove Sprocket and note bearing placement

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DRIVE TRAIN REMOVAL Press bearing out with screwdriver and inspect

Reinstall bearing with open face into Sprocket

Press against closed face of bearing

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DRIVE TRAIN REMOVAL Sprocket Assembles and chain

Drivetrain Locate and remove wheel spacers from 2 wheel side axles

Locate and remove 2 screws at the base of the feed pipe

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DRIVE TRAIN REMOVAL Remove the Vacuum Tube/ Feed pipe assembly.

Locate and remove the 2 screws that attach each axle to the frame.

Frame assembly with Chain tensioner.

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COMPONENTS Product Breakdown

Notes:

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PART NUMBERS

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ASSEMBLY Assemble axle blocks with star washers and screws.

Turn frame upside down and install axle blocks to frame.

Drop gearbox into place with brass inserts pointing up.

Brass Inserts

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ASSEMBLY Attach gearbox with 4 screws in pockets labeled “B”.

Install wheel spacers on double side wheel axle blocks.

Attach Vacuum tube/Feed pipe Assembly to frame with 3 screws.

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ASSEMBLY Install Wheel Sprockets on double side axle.

Wrap chain around front axle sprocket and through tensioner as shown.

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ASSEMBLY Use the diagram on the Vacuum tube to assist with wrap configuration.

Install the 2 sprocket covers.

Locate double side wheel noting one bearing in the outer cavity of each wheel.

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ASSEMBLY Align wheels into sprockets and attach with locking screw.

Locking screw

Attach single side wheel with the same locking screw.

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ASSEMBLY Replace top assembly with 2 screws.

Inspect o-ring on Water management System.

Snap rear housing to Water management System.

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ASSEMBLY Attach Water management System with 3 screws.

Align bottom housing.

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ASSEMBLY Attach bottom housing with 3 screws

Snap hub caps on all wheels.

Attach sweep hose - install nut first then thread back onto sweep hose.

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ASSEMBLY Note the serial number location under the canopy.

Press bag into vacuum tube.

Install quick disconnect.

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Notes:

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3900 SPORT TEARDOWN - 2/12

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