Polaris 3900 Sport

Tear Down

-WARNING- For your safety: This training presentation is a production of Zodiac Pool Systems, Inc. and is designed to serve as a quick overview, and does not replace, alter, or supersede the detailed installation, operation, and service information set forth in the product Owner's Manual. The products reviewed today must be installed and serviced by personnel qualified to install and service the pool equipment depicted in the training. Before starting any installation or service make sure to read the Owner's manual, and all other warning notices that accompany this product, carefully and completely. Failure to follow warning notices and instructions may result in property damage, personal injury, or death. www.zodiacpoolsystems.com. Any reproduction, duplication, retransmission, or copying of this presentation is strictly prohibited.

• Press logo buttons to remove

Quick Disconnect

• Remove Sweep Hose by

twisting nut to release from

hose or by removing the Sweep

Hose Attachment Clamp

• Remove bag by twisting collar

Bag and Sweephose Removal

• Press logo buttons to remove

Quick Disconnect

• Remove bag by twisting collar

• Remove Sweep Hose by

twisting nut to release from

hose or by removing the Sweep

Hose Attachment Clamp

Bag and Sweephose Removal

• Press logo buttons to remove

Quick Disconnect

• Remove bag by twisting collar

• Remove Sweep hose by

twisting nut to release from

hose or by removing the Sweep

Hose Attachment Clamp

Bag and Sweephose Removal

• Remove 3 screws from bottom

of cleaner

• Remove Bottom Housing

Bottom Housing Removal

• Remove 3 screws from bottom

of cleaner

• Remove Bottom Housing

Bottom Housing Removal

• Locate 3 screws labeled “A” and

remove

• Remove Water Management

System and Rear Housing

Water Management System and Rear Housing Removal

• Locate 3 screws labeled “A” and

remove

• Remove Water Management

System and Rear Housing

Water Management System and Rear Housing Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate 4 screws labeled “B” and

remove

• Remove Gearbox and single side

wheel

• Pry hubcap with flat-blade

screwdriver for removal

• Unthread screw to remove wheel

• Pull wheel from gearbox shaft

• Gearbox Assembly Part #39-200

Gearbox Removal

• Locate and remove 2 screws in

order to remove the Top

• Remove Top

• Top Assembly Part #39-003,

includes float

Top Assembly Removal

• Locate and remove 2 screws in

order to remove the Top

• Remove Top

• Top Assembly Part #39-003,

includes float

Top Assembly Removal

• Locate and remove 2 screws in

order to remove the Top

• Remove Top

• Top Assembly Part #39-003,

includes float

Top Assembly Removal

Replacing the 3900 Sport head float:

Remove the three (3) canopy screws

Remove the head float screw

Remove the canopy

The Head Float Kit is backwards compatible

and will replace a 1st generation blue float.

Current Top Housing Part Number: 39-003.

New individual part numbers:

R0538000 Head Float Kit

R0537900 Canopy

R0538100 Housing Top

R0538200 Screw, Self Tapping, Canopy

Replaceable Head Float

Replaceable Head Float

Replacing the 3900 Sport head float:

Remove the three (3) canopy screws

Remove the head float screw

Remove the canopy

The Head Float Kit is backwards compatible

and will replace a 1st generation blue float.

Current Top Housing Part Number: 39-003.

New individual part numbers:

R0538000 Head Float Kit

R0537900 Canopy

R0538100 Housing Top

R0538200 Screw, Self Tapping, Canopy

Replaceable Head Float

Replacing the 3900 Sport head float:

Remove the three (3) canopy screws

Remove the head float screw

Remove the canopy

The Head Float Kit is backwards compatible

and will replace a 1st generation blue float.

Current Top Housing Part Number: 39-003.

New individual part numbers:

R0538000 Head Float Kit

R0537900 Canopy

R0538100 Housing Top

R0538200 Screw, Self Tapping, Canopy

Replaceable Head Float

Replacing the 3900 Sport head float:

Remove the three (3) canopy screws

Remove the head float screw

Remove the canopy

The Head Float Kit is backwards compatible

and will replace a 1st generation blue float.

Current Top Housing Part Number: 39-003.

New individual part numbers:

R0538000 Head Float Kit

R0537900 Canopy

R0538100 Housing Top

R0538200 Screw, Self Tapping, Canopy

Replacing the 3900 Sport head float:

Remove the three (3) canopy screws

Remove the head float screw

Remove the canopy

The Head Float Kit is backwards compatible

and will replace a 1st generation blue float.

Current Top Housing Part Number: 39-003.

New individual part numbers:

R0538000 Head Float Kit

R0537900 Canopy

R0538100 Housing Top

R0538200 Screw, Self Tapping, Canopy

Replaceable Head Float

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Pry hubcaps off double-side

wheels with flat-blade

screwdriver

• Unthread screw to remove

wheel

• Remove wheel

• Remove feed pipe screw for

chain guard (if present)

• Remove wheel sprocket

cover to expose chain

• Remove chain from rear

wheel sprocket

Drive Train - Step 1 of 3

• Remove Sprocket and note

bearing placement

• Press bearing out with

screwdriver and inspect

• Reinstall bearing with open

face into sprocket

• Press against closed face of

bearing

• Sprocket Assemblies and

chain

Drive Train - Step 2 of 3

• Remove Sprocket and note

bearing placement

• Press bearing out with

screwdriver and inspect

• Reinstall bearing with open

face into sprocket

• Press against closed face of

bearing

• Sprocket Assemblies and

chain

Drive Train - Step 2 of 3

• Remove Sprocket and note

bearing placement

• Press bearing out with

screwdriver and inspect

• Reinstall bearing with open

face into sprocket

• Press against closed face of

bearing

• Sprocket Assemblies and

chain

Drive Train - Step 2 of 3

• Remove Sprocket and note

bearing placement

• Press bearing out with

screwdriver and inspect

• Reinstall bearing with open

face into sprocket

• Press against closed face of

bearing

• Sprocket Assemblies and

chain

Drive Train - Step 2 of 3

• Remove Sprocket and note

bearing placement

• Press bearing out with

screwdriver and inspect

• Reinstall bearing with open

face into sprocket

• Press against closed face of

bearing

• Sprocket Assemblies and

chain

Drive Train - Step 2 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Drive Train - Step 3 of 3

Drive Train - Step 3 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Drive Train - Step 3 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Drive Train - Step 3 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Drive Train - Step 3 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Drive Train - Step 3 of 3

• Locate and remove wheel spacers

from 2 wheel side axles

• Locate and remove 2 screws at the

base of the feed pipe

• Remove the Vacuum Tube/Feed

pipe assembly

• Locate and remove the 2 screws

that attach each axle block to the

frame

• Frame assembly with Chain

Tensioner

Product Breakdown

POLARIS®

3900 SPORT

REASSEMBLY

INSTRUCTIONS

• 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

• Attach gearbox with 4 screws

in pockets labeled “B”

• Install wheel spacers on

double side wheel axle blocks

Reassembly – Step 1 of 7

• 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

• Attach gearbox with 4 screws

in pockets labeled “B”

• Install wheel spacers on

double side wheel axle blocks

Reassembly – Step 1 of 7

• 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

• Attach gearbox with 4 screws

in pockets labeled “B”

• Install wheel spacers on

double side wheel axle blocks

Brass

Inserts

Reassembly – Step 1 of 7

• 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

• Attach gearbox with 4 screws

in pockets labeled “B”

• Install wheel spacers on

double side wheel axle blocks

Reassembly – Step 1 of 7

• 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

• Attach gearbox with 4 screws

in pockets labeled “B”

• Install wheel spacers on

double side wheel axle blocks

Reassembly – Step 1 of 7

• Attach Vacuum

Tube/Feedpipe Assembly to

frame with three screws

• Install Wheel sprockets on

double side axles

Reassembly – Step 2 of 7

• Attach Vacuum

Tube/Feedpipe Assembly to

frame with three screws

• Install Wheel sprockets on

double side axles

Reassembly – Step 1 of 7

• Attach Vacuum

Tube/Feedpipe Assembly to

frame with three screws

• Install Wheel sprockets on

double side axles

Reassembly – Step 1 of 7

• Wrap chain around front

axle sprocket and through

tensioner as shown

• Use the diagram on the

vacuum tube to assist with

wrap configuration

• Install the 2 sprockets

covers

• Install the chain guard on

the feed pipe screw.

Reassembly – Step 3 of 7

• Wrap chain around front

axle sprocket and through

tensioner as shown

• Use the diagram on the

vacuum tube to assist with

wrap configuration

• Install the 2 sprockets

covers

• Install the chain guard on

the feed pipe screw.

Reassembly – Step 3 of 7

• Wrap chain around front

axle sprocket and through

tensioner as shown

• Use the diagram on the

vacuum tube to assist with

wrap configuration

• Install the 2 sprockets

covers

• Install the chain guard on

the feed pipe screw.

Reassembly – Step 3 of 7

• Wrap chain around front

axle sprocket and through

tensioner as shown

• Use the diagram on the

vacuum tube to assist with

wrap configuration

• Install the 2 sprockets

covers

• Install the chain guard on

the feed pipe screw.

Reassembly – Step 3 of 7

• Wrap chain around front

axle sprocket and through

tensioner as shown

• Use the diagram on the

vacuum tube to assist with

wrap configuration

• Install the 2 sprockets

covers

• Install the chain guard on

the feed pipe screw.

Reassembly – Step 3 of 7

• Locate double side wheels

noting one bearing in the outer

cavity of each wheel

• Align wheels into sprockets and

attach with locking screw

• Attach single side wheel with

the same locking screw

Reassembly – Step 4 of 7

• Locate double side wheels

noting one bearing in the outer

cavity of each wheel

• Align wheels into sprockets and

attach with locking screw

• Attach single side wheel with

the same locking screw

Reassembly – Step 4 of 7

• Locate double side wheels

noting one bearing in the outer

cavity of each wheel

• Align wheels into sprockets and

attach with locking screw

• Attach single side wheel with

the same locking screw

Reassembly – Step 4 of 7

• Locate double side wheels

noting one bearing in the outer

cavity of each wheel

• Align wheels into sprockets and

attach with locking screw

• Attach single side wheel with

the same locking screw

Reassembly – Step 4 of 7

• Locate double side wheels

noting one bearing in the outer

cavity of each wheel

• Align wheels into sprockets and

attach with locking screw

• Attach single side wheel with

the same locking screw

Reassembly – Step 4 of 7

• Replace top assembly with

two screws

• Snap rear housing to Water

management System

Reassembly – Step 5 of 7

• Replace top assembly with

two screws

• Snap rear housing to Water

management System

Reassembly – Step 5 of 7

• Attach Water Management

System with 3 screws

• Slide bottom housing on

• Attached bottom housing with 3

screws

• Snap hub caps on all wheels

Reassembly – Step 6 of 7

• Attach Water Management

System with 3 screws

• Slide bottom housing on

• Attached bottom housing with 3

screws

• Snap hub caps on all wheels

Reassembly – Step 6 of 7

• Attach Water Management

System with 3 screws

• Slide bottom housing on

• Attached bottom housing with 3

screws

• Snap hub caps on all wheels

Reassembly – Step 6 of 7

• Attach Water Management

System with 3 screws

• Slide bottom housing on

• Attached bottom housing with 3

screws

• Snap hub caps on all wheels

Reassembly – Step 6 of 7

• Attach sweep hose – install

nut first then thread back on

to sweep hose

• Note the serial number

location under the canopy

• Press bag into vacuum tube

• Install quick disconnect

• Reassembly completed

Reassembly – Step 7 of 7

• Attach sweep hose – install

nut first then thread back on

to sweep hose

• Note the serial number

location under the canopy

• Press bag into vacuum tube

• Install quick disconnect

• Reassembly completed

Reassembly – Step 7 of 7

• Attach sweep hose – install

nut first then thread back on

to sweep hose

• Note the serial number

location under the canopy

• Press bag into vacuum tube

• Install quick disconnect

• Reassembly completed

Reassembly – Step 7 of 7

• Attach sweep hose – install

nut first then thread back on

to sweep hose

• Note the serial number

location under the canopy

• Press bag into vacuum tube

• Install quick disconnect

• Reassembly completed

Reassembly – Step 7 of 7

• Attach sweep hose – install

nut first then thread back on

to sweep hose

• Note the serial number

location under the canopy

• Press bag into vacuum tube

• Install quick disconnect

• Reassembly completed

Reassembly – Step 7 of 7

Thank You!