Here's the problem.

I've got a '98 425 Magnum 4x4 and was doing some maintenance the other day. So I followed Polaris' procedure for chain tension. First the center section - no problems. Then the front section - problems. I couldn't get the essentric to tighten the chain enough. After a bent punch and screwdriver later, I surmised that the chain needed to have 1 link removed. Now, after 1 link has been removed the chain is too short - by a hair.

Question;
Does anyone know of a half link for the 520-O-ring chain? If not, am I going to have to buy a new chain?

 

A half link does not work on an o-ring chain worth a darn, not strong enough, although it maybe would be on the front. I wouldn't know where to get one, anyway.

Would it be possible to over-tighten the middle chain just enough to get the front chain re-connected? Then you could back off the adjustment a little to average them out, or would they still be too tight?
Could be you just have to bite the bullet and get a new chain.

 

valerius

Are you sure you couldn't get the front chain tight enough? I was having the same problem, bending punches trying to get it tight. I then had a severe brain cramp and tried to use the engine to move the bearing carrier. After breaking the sprocket and subsequently replacing it, I found a hardened steel pin that I inserted into the bearing carrier and pushed the vehicle backwards and got the bearing carrier to spin. The key to getting the bearing carrier to spin is to get the pin in the hole in the bearing carrier that will allow it the most leverage. Before buying a new chain, I would make sure that it has been fully adjusted first. My bet is that it could have been adjusted more.

 

I hear what your saying. This is what I know to date. I talked to the dealer about how far essentric rotates from one extreme (loose) to the other (tight). He said that it should turn about 1/4. Now I know that dealers sometimes don't know @#it. But this seemed consistent with what I was trying to accomplish. I could only get the essentric to rotate 1/4 from front to back. My first thought was that it was being blocked by dirt and general gunk that clogs things up. However, I rotated this thing front to back several times with some force (not using my engine) to make sure that I was getting the most out of it. This is all before I decided to reduce the length of chain by 1 pin.

I was using the correct hole in the essentric. I had my flashlight and head all up in there looking for this little hole that is called out in the repair manual. So, I'm pretty sure that leverage is a maximum.

I agree with Farmr123, a half link is out of the question. Sidewinder confirmed what Farmr already knew, not strong enough and not available. I think I will try his method of losening the middle to get the front back together and then tighten both simultaneouly until I think they are even. Assuming that neither will be too tight or loose afterwards.

 

valerius

Let us know how Farmer's idea works. I may be in that same position the next time I tighten the chains. I think we will both agree that the three chain design was a crappy design