Zodiac Polaris 3900 Sport User manual

1
3900 Sport
Tear Down Instructions

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TABLEOFCONTENTS
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

4
Remove Sweep hose by
twisting nut to release from
hose
Remove bag by twisting collar
Press logo buttons to remove
Quick Disconnect
BAG AND SWEEP HOSE REMOVAL

5
Remove 3 screws from bottom
of cleaner
Remove Bottom Housing
BOTTOMHOUSINGREMOVAL
Locate3screwslabeled“A” and
remove.

6
RemoveWatermanagement
Systemand Rear Housing
Locate 4 screws labeled “B” and
remove
RemoveGearboxandsingle side
wheel
GEAR BOX REMOVAL

7
Pryhubcap withflat-bladescrew-
driverfor removal
Un-threadscrew toremovewheel
Pullwheel fromgearboxshaft
GEAR BOX REMOVAL

8
GearboxAssembly Part #39-200
GEARBOXCOMPONENTS
Notes:

9
Locateand remove 2 screws
inorderto remove theTop.
RemoveTop
TopAssemblyPart #39-003,
includesfloat.
TOPASSEMBLY REMOVAL

10
Pryhubcap off double-side
wheelswith flat-bladescrew
driver
Un-threadscrew toremove
wheel.
Removewheel.
DRIVETRAINREMOVAL