6.1 special service tools and supplies
Contents
1. Green 7041168 Purple 7041063 White 7041132 Plain 7041021 Blue Green 7041157 Black 7041022 1 25 1 19 should always be inspected for toler COMERESSEDSFRING EENGTITUNCHES ance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces as shown Refer to the spring specification chart for specific free length measurements and tolerances Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement Primary Clutch Springs Secondary Clutch Springs PART COLOR WIRE FREE LENGTH PART DESCRIPTION NUMBER CODE DIAMETER 125 NUMBER 7041021 ism 238 701196 Rea 7041022 140 4 251 7041782 Black 5 coil Proaioes Pupe iss faan eus eous cor Dems we um psa ense swe Desues Green ir sos onze sue Dems secs ir ss peues siemue POLARIS 6 9 CLUTCH Om SHIFT WEIGHTS Shown below are the shift weights which have been designed for or which may be used in the PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their p2. CAUTION Be sure the spider spacer washers are fully seated in the recessed area in the spider Any misalignment will alter clutch balance Inverting the clutch while initially tightening the spider will help position the washers 6 Install shift weights using new lock nuts on the bolts 7 Reinstall clutch spring Ju thy i umm Tee a n Nut on trailing side 6 16 8j POLARIS CLUTCH CX DRIVE CLUTCH ASSEMBLY CONT 8 Reinstall cover aligning X mark with other marks Torque cover bolts evenly to specification Spider Torque 200 ft Ibs 276 Nm Cover Screw Torque 90 in Ibs 10 4 Nm DRIVE BELT TENSION NOTE Pinch the sheaves lightly together with clamp to preventthe beltfrom being pushed into the driven sheave 1 Place astraight edge on top of the belt between drive and Straight Edge driven clutch 2 Push down on drive belt until it is lightly tensioned Eder 255mm 3 Measure belt deflection as shown in photo Belt Deflection Tension 1 1 8 2 9 cm 1 1 4 3 2 cm If belt deflection is out of specification adjust by removing or adding shims between the driven clutch sheaves S Remove shims to decrease belt deflection S Add shims to increase belt deflection See Driven Clutch Disassembly Inspection Pages 6 25 6 27 NOTE Atleastone shim mustremain between the inn
3. 12 13 14 15 16 PVT ASSEMBLY Inspect PVT inner cover to engine seal Replace if cracked or damaged Place a new seal on transmission input shaft Apply RTV silicone sealantto outside edge of inner cover to engine seal to ensure a water tight fit between the seal and the cover on engine side Surfaces must be clean to ensure adhesion of silicone sealant Reinstall cover and tighten rear cover bolts just enough to hold it in place Fitlip of inner cover seal A to engine Install seal retainer plate and tighten screws securely Torque rear inner cover bolts B to specification Inner Cover Bolt Torque Rear 12 ft Ibs 16 6 Nm Driven Clutch Retaining Bolt Torque 17 ft Ibs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 ft Ibs 55 Nm Install clutch offset spacer on transmission input shaft Clean splines inside driven clutch and on the transmission input shaft Apply a light film of grease to the splines on the shaft Install the driven clutch washer lock washer and retaining bolt Torque to specification Clean end of taper on crankshaft and the taper bore inside drive clutch Install drive clutch and torque retaining bolt to specification Reinstall drive belt noting direction of rotation Ifa new belt is installed install so numbers can be easily read Replace PVT outer cover rubber gasket with the flat side out C Reinstall PVT outer cover and secure with scre
4. MOVEABLE SHEAVE BUSHING INSPECTION l Inspectthe Teflont coating on the moveable sheave bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflont is visible on the bushing Refer to bushing replacement in this chapter POLRRIS CLUTCH ama DRIVEN CLUTCH DISASSEMBLY INSPECTION EBS CAUTION The driven clutch mustbe disassembled from the helix end to lessen the chance of damage to seals in the one way clutch Review all information below before proceeding ONE WAY CLUTCH PRELIMINARY INSPECTION DRIVEN 1 With drive belt removed and transmission in neutral hold the outer sheave and rotate the inner sheave of the driven clutch moveable in a counterclockwise direction as shown atright The sheave should rotate on the shaft with only a slight amountof drag There should not be any binding or rough spots 2 When rotated clockwise the inner moveable sheave should lock to the shaft and outer sheave without slipping 3 Remove driven clutch from the transmission input shaft Do not disassemble the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side or the one way clutch seals may be damaged Do not disassemble from this side 6 3 6 1 Ge POLARIS CX CLUTCH DRIVEN CLUTCH DISASSEMBLY INSPECTION CONT 4 Push helix inward Remove snap ring washer helix and s
5. CLUTCH CK DRIVE CLUTCH MOVEABLE SHEAVE BUSHING REMOVAL CONT 6 Tum sheave and puller barrel together counterclockwise on puller rod until bushing is removed 7 Remove nut from puller rod and set aside 8 Pullbushing removal tool and adapter from puller rod Remove bushing from tool and discard DRIVE CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION Place main adapter Item 8 on puller Apply Loctitet 680 retaining compound to the back side of new bushing Push bushing into center of sheave on tower side by hand Bushing PN 3576504 Loctitet 680 PN 2870584 Insert installation tool Item 2 into center of sheave and with towers pointing away from vise slide sheave onto puller rod Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheave and barrel together counterclockwise until bushing is seated Remove nut from puller rod and set aside Remove sheave from puller Remove installation tool 6 22 POLARIS Gm CLUTCH DRIVE CLUTCH COVER BUSHING REMOVAL l Install main adapter Item 8 on puller Piston Pin Puller PN 2870386 Main Adaptor 2 From outside of clutch cover insert removal tool Item 3 into cover bushing 3 With inside of cover toward vise slide cover onto puller 4 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 5 Tur
6. POLARIS 6 13 CLUTCH O SPIDER REMOVAL 1 Install clutch in holding fixture and loosen the spider counterclockwise using spider removal tool Clutch Holding Fixture PN 2871358 Drive Clutch Spider Removal Tool PN 2870341 NOTE Itis importantthatthe same number and thickness of washers are reinstalled beneath the spider during as sembly Be sure to note the number and thickness ofthese washers To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness washers Moveable Sheave Bushing Inspection 2 Inspectthe Teflont coating on the moveable sheave bushing Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflont is visible on the bushing Refer to bushing replacement in this chapter 6 14 G PGLRRIS CLUTCH CX ROLLER PIN AND THRUST WASHER INSPECTION 3 Inspectall rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation
7. moveable sheave 3 Insert spring tab into proper hole in helix See specifications at the beginning of this section The driven clutch helix moveable assembly has several different spring locations which affect clutch shifting and RPMs The greatest amount of spring tension will raise Moveable S pring engine RPMs during clutch upshift and allow quicker Example Helix Sheave Tension backshift or downshift when pulling or negotiating a hill 2 1 Heavy for example The least amount of tension will create a 5 pring slower downshift and a harder upshift 2 2 Position 1 1 2 3 1 2 1 3 Soft Refer to General Information Chapter 1 for driv en clutch spring color and production setting 4 Line up boss spline and push helix down until it engages the splines 1 2 to 3 4 5 While holding downward pressure on helix wind moveable sheave counterclockwise approximately 1 3 turn 120 6 Push helix into place and install snap ring 6 28 OO POLARIS Gm CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING REMOVAL NOTE Bushings are installed atthe factory using Loc tite In orderto remove the bushing it will be necessary to apply heat A press can be used to remove and install some of the bushings Be sure to support the sheave or cover as close as possible to the bushing bore when using a press l Install main adapter Item 8 onto puller 2 Insertadapter reducer Item 9 onto puller sliding it inside
8. 4 Rubber backed buttons can and should be used in all ATV clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin It is recommended to switch all buttons to the rubber version during service POLARIS 6 15 CLUTCH Gm DRIVE CLUTCH ASSEMBLY NOTE It is important that the same number and thick ness of washers are reinstalled beneath the spider dur ing assembly The Teflont bushings are self lubricat ing Do notapply oil or grease to the bushings 1 Reassemble drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly a X orthe marks that were made earlier on cover b spider making sure spacer washers are installed underneath spider and positioned properly in recess C X or the marks that were made earlier under weight 2 Install moveable sheave onto fixed sheave 3 Install spider spacers Use same quantity and thickness as were removed 4 Compress spider buttons for each tower and install spider making sure that X orthe marks that were made earlier on spider aligns with X orthe marks that were made earlier in moveable sheave 5 Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave Referto Page 6 1 for torque specification
9. operating tem peratures and longer component life Driving at low RPM or low ground speed Warm engine atleast 5 min then with transmission in neutral at approximately 3 7 MPH advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch engagement Towing P ushing at low RP M low ground Use Low Range only speed Stuck in mud or snow Shift the transmission to Low Range carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle over turn Climbing over large objects from a Shift the transmission to Low Range carefully use fast stopped position aggressive brief throttle application to engage clutch WARN ING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion Shift the transmission to neutral Using the throttle vary the into the PVT system engine rpm from idle to full throttle Repeat several times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction For inspection of clutch components please contact your P o laris dealer Poor engine performance Fouled plugs foreign material in gas tank fuel lines or carbu retor Contact you dealer for
10. the main adapter Main Adapter 3 Remove ramp buttons from moveable sheave Adapter Reducer 4 Using a hand held propane torch apply heat directly on bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In orderto avoid se rious burns wear some type of insulated gloves for the rest of the removal process POLARIS 6 29 CLUTCH Gm DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING REMOVAL CONT 5 Working from the top install bushing removal tool Item 5 into center of clutch sheave with smaller diameter toward bushing to be removed See illustration at right Bushing Removal Tool 5 6 Install sheave onto puller 7 Install nut onto puller rod and tighten by hand Turn puller barrel for further tension if needed 8 Turn clutch sheave counterclockwise until bushing is removed Repeat Steps 5 8 for other bushing 9 Remove nut from puller rod and set aside 10 Remove adapters from puller 11 Remove bushing and removal tool from adapters Discard bushing 6 3 0 1 8p POLARIS CLUTCH DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING INSTALLATION 1 Working from the top insert adapter number ten onto puller See illustration at right 2 Start new bushing evenly in moveable sheave Apply Loctitet 680 retaining compound to the back side of new bushing las v4 FA OL H I ee
11. 654 STD PN 2872292 EBS 1 81 0 1 16 3 2mm 0 1 6 mm Measure offset above and below centerline Offset Alignment Tool should contact rear edge of driven clutch sheave Driven Clutch Offset To adjust add or remove washers from behind the driven clutch POLARIS GT CLUTCH DRIVE CLUTCH BUSHING SERVICE Polaris Kit Clutch Bushing Replacement Tool Kit PN 2871226 Item Qty Part Description Part No 2 1 P 90 Drive Clutch and Driven Clutch 5020628 Bushing Installation Tool 3 1 Drive Clutch Cover Bushing Removal and 5020629 Installation Tool for all drive clutches 5 1 P 90 Driven Clutch Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 DRIVE CLUTCH MOVEABLE SHEAVE BUSHING REMOVAL 1 Install handle end of piston pin puller securely into bench vise and lightly grease puller threads Piston Pin Puller PN 2870386 2 Remove nut from puller rod and set aside 3 Install main adapter Item 8 onto puller Piston Pin Puller PN 2870386 4 Insert adaptor 2 into bushing from belt side as shown With towers pointing toward vise slide sheave and bushing onto puller rod 5 Install nutremoved in Step 2 onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Nutis left hand thread POLARIS 6 21
12. CLUTCH CX SPECIAL SERVICE TOOLS AND SUPPLIES PART NUMBER 2870506 9314177 2871358 2870341 2870654 SPECIAL SUPPLIES PART NUMBER l octitet 7680 eot satanas t RAE 2870584 RTV Silicone Sealer sese 2870661 Loctite Gasket Remover 2870601 PVT SYSTEM FASTENER TORQUES Drive Clutch Retaining Bolt 40 ft Ibs 54 Nm Driven Clutch Retaining Bolt 17 ft Ibs 23 Nm PVT Inner Cover Bolts 0 0 ce eee 12 ft Ibs 16 Nm Drive Clutch Spider Standard Clutch 200 ft Ibs 271 Nm Drive Clutch Spider EBS Clutch 185 ft Ibs 251 Nm Drive Clutch Spider Lock Nut Plastic 5 ft lbs 6 5 Nm Drive Clutch Cover Plate 000 90 in Ibs 10 Nm Refer to General Chapter 1 for Specifications by model PELARIS 6 1 CLUTCH Gm PVT OPERATION The Polaris variable transmission P VT consists of three major assemblies 1 drive clutch 2 drive belt and 3 driven clutch The internal components of the drive clutch and driven clutch control clutch engagement for initial vehicle movement clutch upshifting and backshifting During the development of an ATV the PVT system is matched first of all to the engine power curve then to average riding conditions and to vehicle design usage Modifications to the P VT or variations of components at random are ne
13. Inspection Replace the bushing if more brass than Teflont is visible on the surface of the bushing 8 Check for movement of the driven clutch shaft in the one way clutch If the shaft can be moved laterally or if the one way clutch does not function properly as described in Step 1 and 2 on Page 6 36 replace driven clutch assembly 6 383 H_ S mm POLARIS Oe CLUTCH BUSHING REPLACEMENT EBS DRIVE EBS CLUTCH BUSHING REMOVAL AND INSTALLATION Use Tool Kit EBS Bushing Replacement Kit PN 2201379 The contents of this kit include Item Qty PartDescription Part No A B 1 EBS Drive Clutch and Driven Clutch 5132027 Puller Tool C 1 EBS Drive Clutch and Driven Clutch 5132501 Puller Nut D 1 EBS Main Adapter 5132029 E 1 EBS Bushing Removal Tool 5132028 1 Instruction 9915111 Also required Clutch Bushing Removal Installation Tool Kit PN 2871226 ATV Clutch Kit or 2871025 For all clutches Piston pin puller PN 2870386 REMOVAL AND INSTALLATION INSTRUCTIONS NOTE Bushings are installed at the factory using Loctitet 609 In orderto remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to instal ling new bushing EBS Drive Clutch Moveable Sheave Bushing Removal 1 Remove clutch as outlined previously in this chapter 2 Install handle end of Piston Pin Puller PN 2870386 securely into bench vise and li
14. Lh phd OG e bose a Adapter Number Ten 3 Install sheave onto puller with new bushing upward as shown Install adaptor number two POLARIS MC 6 31 CLUTCH Gm DRIVEN CLUTCH MOVEABLE SHEAVE BUSHING INSTALLA TION CONT 4 Install nut onto puller rod and hand tighten against installation tool 5 Turn clutch sheave counterclockwise until bushing is seated 6 Remove nut from puller rod and set aside 7 Remove installation tool and clutch sheave from puller 8 Repeat installation procedure for other moveable bushing 6 32 POLRRIS Gm CLUTCH ENGINE BRAKING SYSTEM EBS EBS Exploded View Drive Clutch Assembly m dt Nm di N Retaining sere E Ring d 2 25 PTFE NN 7 Washer Flat Spacer ar 7 One Way Clutch Drive Ramp Bushing Shift Weights Brass Washer Compression Spring Cover Torque to Bushing 185 Ft Lbs 4 Bushing Spring Screw Bushing Roller DW Roller Bushing ae oe m Vi Assembly Drive Belt m d Spider Lock Nut pt ci Bolts Lock 2 Wiehe PTFE Washer yee Retaining Ring ge d Eum zi 3 p Driven Clutch Assembly d POLARIS 6 33 CLUTCH ama Mark with permanent marker before disassembly Ce 0000 One way clutch EBS Drive Clutch ONE WAY CLUTCH INSPECTION DRIVE CLUTCH 1 Rotate one way clutch clockwise as viewed from the cover plate side The clutc
15. e Engine RPM above specified operating range Drive clutch shift weights incorrect for ap plication too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slippage Harsh drive Drive belt worn too narrow clutch engage ment Excessive belt sheave clearance with new belt Drive belttums Wrong belt for application over Clutch alignment out of spec Engine mount broken or loose PVT cover Plugged air intake or outlet overheating melting Belt slippage due to water oil grease etc rubbing on cover Clutches or weight being applied to cover while in operation High vs low range Water ingestion Cover seals or ducts leaking Operator error POLRRIS Replace with recommended spring Install correct shift weight kit to match engine application Replace spring refer to proper installation location a Disassemble drive clutch inspect shift weights for wear and free operation b Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace belt a Replace ramp buttons b Inspect movable sheave for excessive bushing clearance replace Replace the clutch Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble withoutthe spring and move sheaves through entire range to further deter
16. e counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated Remove nut from puller rod and set aside Remove sheave from puller 10 Remove installation tool EBS Clutch Cover Bushing Removal T 2 3 Install main adapter Item 8 on puller Install adapter reducer Item 9 From outside of clutch cover insert removal tool Item 3 into cover bushing With inside of cover toward vise slide cover onto puller Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free Remove nut from puller rod and set aside Remove bushing and bushing removal tool from puller Discard bushing EBS Clutch Cover Bushing Installation Qui MI Se S m Apply Loctitet 609 evenly to bushing bore in cover CX USHING REPLACEMENT EBS DRIVE CONT Puller Tool A B Side A toward sheave Bushing E I T Piston Pin Main Adapter 8 F Puller EBS Drive Clutch Moveable Sheave Bushing Installation Adapter Reducer 9 Main Adapter 8 Piston P in Puller EBS Drive Clutch Cover Bushing Removal Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover With main adapter on puller insert cover onto puller rod placing outside of cover toward vise Install nu
17. e driven clutch The forces in the driven clutch will now affect the upshift DRIVEN CLUTCH OPERATION The driven clutch primarily senses torque Itopens and closes according to the forces applied to it from the drive belt and the transmission input shaft If the torque resistance on the input shaft is greater than the load from the drive belt it will keep the drive belt outward at the top of the driven clutch sheaves As the throttle setting and engine horsepower increase there will be a greater load on the drive belt pulling the belt down into the driven clutch and up on the drive clutch This action which increases the driven clutch speed is called upshifting If the throttle setting remains the same and the vehicle is subjected to a heavier load the driven clutch senses this load moving the belt back up on the sheaves of the driven clutch and down into the sheaves of the drive clutch This action which decreases the driven clutch speed is called downshifting In situations where loads vary such as uphill and downhill and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM Atfull throttle a perfectly matched PVT system will hold the engine RPMs at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respectthe PVT system is similar to a power governor Rather than change throttle position as a governor does the PVT system c
18. erand outer sheave of the driven clutch If proper belt deflection cannot be obtained measure drive belt width length and center distance of drive and driven clutch outlined in this sec tion all have an effect on belt deflection POLARIS MCC 6 17 CLUTCH CX DRIVE BELT REMOVAL INSPECTION 1 Remove outer PVT cover as described in PVT Disassembly 2 Mark drive belt direction of rotation so that it can be installed in the same direction NOTE Normally positioned so part numbers are easily read 3 To remove drive belt apply brake pull upward and rearward on belt to open driven clutch sheaves pull out and down on belt to slip over the driven clutch outer sheave 4 Measure belt width and replace if worn severely Generally belt should be replaced if clutches can no longer be adjusted to provide proper belt deflection S The top edges have been trimmed on some drive belts It will be necessary to project the side profiles and measure from cornerto corner S Place a straight edge on each side of the drive belt S Place another straight edge on top of belt S Measure the distance where the side straight edges intersectthe top as shownin the illustra tion at right 5 Inspect belt for loose cords missing cogs cracks TRE abrasions thin spots or excessive wear Replace if l necessary 6 Inspectbeltfor hour glassing extreme circular wear i in at least one spot and on both sides of the belt Hour g
19. further service information GENERAL RANGE OPERATION GUIDE Low Range Heavy pulling basic operational speeds less LINES than 7 MPH riding through rough terrain swamps mountains etc low ground speeds High Range High ground speeds speeds above 7 MPH 6 4 O POLARIS Gm CLUTCH PVT DISASSEMBLY NOTE Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement See Page 6 8 1 Remove seat 2 Remove or loosen rear cab fasteners as necessary to gain access to PVT outer cover 3 Remove PVT air outlet duct hose 4 Remove outer cover screws Refer to Page 6 8 5 Mark the drive belt direction of rotation and remove drive belt See Page 6 18 for drive belt removal 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Drive Clutch Holder PN 9314177 POLARIS 65 CLUTCH CX PVT DISASSEMBLY CONT 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary Driven Clutch Puller PN 2870913 8 Remove driven clutch offset spacers from the transmission input shaft 9 Remove screws and retainer plate 10 Remove inner cover retaining bolts at rear of cover 11 Remove coveralong with foam sealon back of coveror shaft 6 6 G9 POLARIS CX 1 10 11
20. ghtly grease puller threads Puller Tool A B 3 Remove nut from puller rod and set aside Side A toward Nut C 4 Install puller adapter Item 10 from the Clutch Bushing sei p Replacement Tool Kit PN 2871226 5 Install main adapter Item D onto puller 6 With towers pointing toward the vise slide sheave onto puller rod 7 Install removal tool Item A B into center of sheave with A side toward sheave 8 Install nut C onto end of puller rod and hand tighten a Turn puller barrel to increase tension on sheave if Puller needed Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 9 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller 10 Remove nut from puller rod and set aside 11 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard POLARIS 6 39 CLUTCH EBS Drive Moveable Bushing Installation 8 9 Place main adapter Item 8 on puller Apply Loctitet 609 evenly to bushing bore inside moveable sheave Set bushing in place on sheave Insert installation puller tool Item A B with A side down into center of bushing With towers pointing upward slide sheave bushing and tool onto puller rod Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheav
21. h should rotate on the shaft with only slight amount of drag There should not be any binding or rough spots When rotated counterclockwise the clutch should lock to the shaft without slipping If problems are noted in either direction continue with disassembly DRIVE CLUTCH INSPECTION NOTE Remove cover spring and spider following in structions for standard non EBS drive clutch then pro ceed as follows 1 Remove moveable sheave spacer sleeve and the brass washer Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged Brass Washer Thickness Standard 030 76mm Service Limit 025 64mm 6 34 1 O POLARIS CLUTCH CX DRIVE CLUTCH INSPECTION CONT 2 Remove moveable sheave 3 Lift one way clutch off shaft Replace as an assembly if worn damaged or if problems were noted on Page 6 34 4 Inspect surface of shaft for pitting grooves or damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly if shaft is worn or damaged Shaft Diameter Standard 1 3745 1 375 Service Limit 1 3730 5 Remove 2 1 2 PTFE washer from shaft Visually inspect the washer for damage Measure the thickness and compare to specification Replace if worn or damaged PTFE Washer Thickness Standard 030 76mm Service Limit 025 64mm
22. hanges engine load requirements by either upshifting or downshifting 6 2 POLARIS Gm CLUTCH PVT MAINTENANCE INSPECTION Undernormaloperation the P VT system will provide years oftrouble free operation P eriodic inspection and main tenance is required to keep the system operating at peak performance The following list of items should be in spected and maintained to ensure maximum performance and service life of PVT components Referto the trou bleshooting checklist at the end of this chapter for more information l BeltTension Drive to Driven Clutch Offset Belt Width See Pages 6 17 6 21 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pages 6 10 6 12 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustration below and on the following pages The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The opening for this intake ductis located ata high point on the vehicle location varies by model The intake duct draws fresh air through a vented cover All connecting air ducts as well as the inner and outer covers must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent wa
23. he critical nature and precision balance incorporated into the PVT system itis absolutely essential that no attempt at disassembly or repair be made without factory au thorized special tools and service procedures POLARIS CLUTCH Good 6 11 CLUTCH DRIVE CLUTCH EXPLODED VIEW Drive Clutch CEE Teflon coated ai P brass bushing EOST Teflon coated i brass bushing Mark with permanent marker before disassembly EBS Drive Clutch Spider Lock Nut Brass Washer PTFE Washer One Way Clutch Spacer Sleeve Mark with permanent marker before disassembly 6 12 O POLARIS CLUTCH CX DRIVE CLUTCH DISASSEMBLY 1 Using a permanent marker mark the cover spider and moveable and stationary sheaves for reference The X s may not have been in alignment before disassembly 2 Remove cover bolts evenly in a cross pattern and remove cover plate 3 Inspectcover bushing A The outer cover bushing is manufactured with a Teflont coating Bushing wear is determined by the amount of Teflon remaining on the bushing Cover Bushing Inspection Replace the cover bushing if more brass than Teflont is visible on the bushing Refer to bushing replacement in this chapter 4 Inspectarea on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 9
24. lassing occurs when the drive train does not move and the drive clutch engages the belt Belt Width New 1 174 1 188 2 98 3 02 cm Wear Limit 1 125 2 86 cm 6 18 POLARIS CLUTCH CX DRIVE BELT REMOVAL INSPECTION CONT 7 Measure belt length with a tape measure around the outer circumference of the belt Belts which measure longer than nominal length may require driven shimming or engine adjustment for a longer center distance to obtain proper belt deflection Belts which measure shorter than nominal length may require driven shimming or a shorter center distance Remember proper belt deflection is the desired goal not a specific center distance Center 8 Replace belt if worn past the service limit Belts with Distance 1 thin spots burn marks etc should be replaced to eliminate noise vibration or erratic P VT operation Clutch Center Distance See Troubleshooting Chart at the end of this chapter 10 1 05 254 2 5 1 3mm for possible causes NOTE Ifa new beltis installed Belt Nominal Length 40 875 3 16 check belt deflection 103 8 cm 48 cm DRIVE BELT INSTALLATION 1 Loop belt over drive and over top of driven sheave 2 While pushing down on top of belt turn the back or moveable driven sheave clockwise 3 The belt then should be able to be pushed down into and between the sheaves NOTE Be sure to position belt so par
25. mine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake clearner install new belt Replace belt Perform belt sheave clearance adjustment with shim wash ers beneath spider Replace with correct belt Adjust alignment offset Inspect adjust or replace Clear obstruction Inspectsystem Clean repair or replace as necessary Seal PVT system ducts Remove weight Inform operator Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner s Safety and Maintenance Manual Find leak and repair as necessary Instruct operator on guidelines for operation in wetterrain as outlined in Owner s Safety and Maintenance Manual 6 43 CLUTCH ama TROUBLESHOOTING Situation Probable Cause Beltslippage Belt worn out Replace belt Water ingestion Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean Belt burnt thin Abuse continued throttle application when Caution operator to operate machine within guidelines spots vehicle is stationary excess load Dragging brake Vehicle operated with park brake on Inspect brake system Slow easy clutch engagement Fast effective use of throttle for efficient engagement PVT noise Belt wom or separated thin spots loose Replace bel
26. n clutch cover counterclockwise on puller rod until bushing is removed 6 Remove nut from puller rod and set aside 7 Remove bushing and bushing removal tool from puller Discard bushing POLARIS 6 23 CLUTCH CX DRIVE CLUTCH COVER BUSHING INSTALLATION 1 ApplyLoctitet 680 retaining compound to the back side of new bushing Working from inside of cover insert bushing and bushing installation tool into center of clutch cover Bushing PN 3576510 Loctitet 680 PN 2870584 2 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 3 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 4 Tum clutch cover and barrel together counterclockwise on puller rod until bushing is seated 5 Remove nut from puller rod and take installation tool and clutch cover off rod 6 24 O POLARIS Oe CLUTCH DRIVEN CLUTCH DISASSEMBLY INSPECTION NON EBS 2025 Used to adjust ee belt tension One must always be installed CAUTION Wear eye protection when removing snap ring to prevent serious personal injury 1 Apply and hold downward pressure on the helix or place driven clutch in Clutch Compression Tool PN 8700220 2 Remove snap ring retainer 3 Note location of spring and remove helix 4 Note location of spring in the mo
27. ositioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern 1666 PN 5630418 50 gr PN 5630279 PN 5630095 PN 5630509 43 gr 53 gr 55 gr 9 10 MF PN 5630513 PN 5630709 PN 5630710 PN 5630711 50 5 gr 44 gr 46 gr 479r POLARIS 6 10 CKO SHIFT WEIGHT INSPECTION 1 Remove shift weight bolts and weights Inspect as shown The contact surface of the weightshould be smooth and free of dents or gall marks Inspectthe weight pivot bore and pivot bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection Page 6 15 Broken Worn BUTTON TO TOWER CLEARANCE INSPECTION 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See spider removal Page 6 14 Button to Tower Clearance 000 0011 2 Inspect sheave surfaces Replace the entire service clutch if worn damaged or cracked The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch as sembly All PVT system maintenance repairs must be per formed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual Because of t
28. pring The spring is a compression spring only and has no torsional wind NOTE Rotating the moveable sheave so that the roll ers are notin contact with either helix ramp surfaces will lessen the effort needed to push helix inward 5 Remove spring seat washer and inspectfor wear or damage Replace if worn 6 Inspect surface of rollers for flat spots and wear Rollers must rotate freely on pins withoutexcessive clearance Check the roller pin and roller bore for wear and replace if necessary NOTE ROLLER PIN DISASSEMBLY New roller re taining bolts have a dry locking agent applied to the threads Before attempting to remove the roller pins heatthe threaded area lightly with a propane torch Use a high quality hexagonal wrench Allent in good con dition to avoid screw damage A small amount of valve grinding compound can be applied to the tip of the hex wrench to ensure a tightfit Always use new bolts if they are removed for inspection Apply Loctitet 680 retain ing compound sparingly to the tapered head portion of the roller retaining screws Do notallow locking agent to contact the inside of the rollers Do not lubricate the roller or roller pin POLRRIS Heat Area Roller Lightly Apply Loctite 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws 6 37 CLUTCH CX DRIVEN CLUTCH DISASSEMBLY INSPECTION CONT 7 Inspect moveable sheave bushing for wear Moveable Sheave Bushing
29. puller rod Install nut C onto puller rod and hand tighten against installation tool Turn clutch sheave counterclockwise until bushing is seated Remove nut C lefthand thread from puller rod and set aside Remove installation tool and clutch sheave from puller POLARIS ISN a Bushing Removal Tool E Il 2 Puller Tool A B Side B toward sheave Bushing Puller Adapter 10 EBS Driven Clutch Bushing Installation 6 41 CLUTCH CX USHING REPLACEMENT EBS DRIVEN CONT EBS Driven Backside Outer Bushing Removal Install main puller adapter Item 8 onto puller Install adapter reducer Item 9 Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to avoid serious burns wear some type of insulated gloves for the rest of the removal process 4 5 10 Flip sheave over onto puller Install bushing tool Item 2 Install lefthand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed Turn clutch sheave counterclockwise until bushing is removed and sheave comes free Remove nut C lefthand thread from puller rod and set aside Remove adapters from puller Remove bushing and removal tool from adapters Discard bushing EBS Driven Backside Outer Bushing Installation l 2 3 Install puller adap
30. t belt Broken or worn clutch components cover Inspectand repair as necessary hitting clutches Engagement Thin spots on belt worn belt Replace belt Refer to belt burnt troubleshooting and instruct erratic or stabby operator Drive clutch bushings stick Inspect and repair clutches POLRRIS 6 44
31. t number is easily read POLARIS 6 19 CLUTCH CLUTCH ALIGNMENT 1 Remove belt and install offset alignment tool as shown 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 If the distance is greater than 1 8 or less than 1 16 clutch alignment must be adjusted as follows 3 Remove drive and driven clutch See PVT Disassembly Pages 6 5 6 6 4 Remove PVT inner cover 5 Loosen all engine mounts Move front of engine to the right or left slightly until alignment is correct 6 Tighten engine mounts and verify alignment is correct 7 Measure belt deflection and measure offset both above and below sheave centerlines Adjust if necessary NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mountto increase the distance at point A If a shim is pres ent it can be removed to decrease the distance at point A Shim Kit PN 2200126 CLUTCH OFFSET Important Inspect clutch alignment and center distance be fore adjusting offset 1 Install offset alignment tool as shown Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolttorqued Adjust offset by adding or removing spacer washers between back of driven clutch and spacer as shown Spacer Washer PN 7556401 0 6 2 CX Offset Alignment Tool PN 2870
32. t on rod and hand tighten Turn puller barrel to apply more tension if needed Turn clutch cover counterclockwise on puller rod until bushing is seated Remove nut from puller rod and take installation tool and clutch cover off rod 6 40 POLRRIS CLUTCH CE BUSHING REPLACEMENT EBS DRIVEN EBS Driven Bushing Removal 1 Install puller adapter Item 10 onto puller 2 InsertEBS main adapter Item D onto puller See Ill 1 3 Install bushing removal tool Item E into center of clutch sheave See Ill 2 4 Install sheave onto puller 5 Install left hand nut onto puller rod and tighten by hand Turn puller barrel for further tension if needed 6 Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to avoid serious burns wear some type of insulated gloves for the rest of the removal process 7 10 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free Remove nut C lefthand thread from puller rod and set aside Remove adapters from puller Remove bushing and removal tool from adapters Discard bushing EBS Driven Bushing Installation Slide adapter Item 10 onto puller Apply Loctitet 609 evenly to bushing bore inside moveable sheave Install sheave onto puller belt surface up Place new bushing on side B of installation tool Item A B and slide both over
33. ter Item 10 onto puller Install adapter Item 9 onto puller Apply Loctitet 609 evenly to bushing bore inside moveable sheave Install sheave face down on puller Install new bushing on installation tool Item 2 and install assembly into sheave Install left hand thread nut C onto puller rod and hand tighten against installation tool Turn clutch sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated Remove nut C left hand thread from puller rod and set aside Remove installation tool and clutch sheave from puller 6 42 Heat Bushing Surface Prior To Installation Removal OF Bushings Bushing Tool 2 Reducer 9 Main Adapter 8 EBS Driven Clutch Outer Bushing Removal Nut C Bushing Va Tool 2 Bushing A i u EBS Driven Clutch Outer Bushing Installation GE POLARIS CX TROUBLESHOOTING CLUTCH Situation Probable Cause Engine RPM below specified operating range although engine is prop erly tuned Wrong or broken drive clutch spring Drive clutch shift weight too heavy Driven clutch spring broken or installed in wrong helix location Erratic engine operating RPM during accelera tion or load vari ations Drive clutch binding Belt worn unevenly thin burnt spots Driven clutch malfunction Sheave face grooved Incorrect drive clutch spring too high Spring rat
34. ter and other contaminants from entering the PVT area This is especially critical on units subjected to frequent water forging PVT DRYING If water is ingested shift transmission to neutral and rev engine slightly to expel the moisture and air dry the belt and clutches Allow engine RPM to settle to idle speed shift transmission to lowest available range and test for belt slippage Operate ATV in lowest available range for a short period of time until PVT system is dry POLARIS 6 3 CLUTCH ama PVT OVERHEATING During routine maintenance or whenever P VT system overheating is evident it s importantto check the inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will significantly increase P VT system operating temperatures The ATV should be operated in LOW RANGE when pulling or plowing heavy loads or if extended low speed operation is anticipated Clutch Drive Belt amp Cover Related Issues Diagnosis Possible Causes Solutions What to do Loading the ATV into a pickup or tall trailer Shift transmission to low range during loading of the ATV to Starting out going up a steep incline When starting out on an incline use low range or dismount the d ATV after first applying the park brake and perform the K turn Insufficient warm up of ATVs exposed to low Drive at higher speed or use Low Range The use of Low ambient temperatures Range is highly recommended for cooler PVT
35. veable sheave and remove the spring POLARIS CLUTCH ama DRIVEN CLUTCH DISASSEMBLY INSPECTION CONT 5 Check alignment of tabs on spring Replace the spring if tabs are misaligned or the spring coils are distorted Tabs Aligned 6 Inspectramp buttons in the moveable sheave and replace if worn NOTE The ramp buttons are secured by Torxt screws T20 7 Remove moveable sheave and note the number of spacer washers One spacer must remain Belt deflection adjustment between the sheaves when adjusting belt washers deflection 6 26 O POLARIS CX DRIVEN CLUTCH DISASSEMBLY CLUTCH INSPECTION CONT 8 Inspect the Teflont coating on the moveable sheave bushing Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflon is visible on the bushing Re fer to bushing replacement in this chapter 9 Inspect driven clutch faces for wear or damage 10 Clean and inspect splines on helix and transmission input shaft 11 Lube splines with a light film of grease Do not lubricate the bushings POLARIS Inspect bushings for wear 6 27 CLUTCH OO DRIVEN CLUTCH ASSEMBLY 1 Install moveable sheave with spacer washers Important At least one spacer washer must be installed Teflon bushings are self lubricating Do not apply oil or grease to the bushings 2 Installspring inserting spring tab into proper hole in
36. ver recommended Proper PVT system setup and careful inspection of existing components must be the primary objective when troubleshooting and tun ing A All PVT system maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as out lined in this manual Because of the critical nature and precision balance incorporated into the PVT sys tem it is absolutely essential that no attempt at disassembly or repair be made without factory autho rized special tools and service procedures DRIVE CLUTCH OPERATION The drive clutch primarily senses engine RPM The two major components which control its shifting function are the shift weights and the coil spring When the engine RPM is increased the centrifugal force of the shift weights working against the coil spring increases When this force reaches a force higher than the preload in the spring the moveable sheave of the drive clutch will move inward contacting the drive belt The force will pinch the belt between the spinning sheaves and cause the drive belt to move This movementin turn rotates the driven clutch At light throttle settings the drive belt will stay low in the drive clutch and high in the driven clutch As engine RPM increases So does the centrifugal force on the shift weights causing the drive beltto be forced upward in the drive clutch and downward into th
37. ws Reinstall rear cab assembly and seat POLARIS CLUTCH Seal this edge to cover on engine side Seal outer edge to cover with RTV silicone sealant Flat edge out Toward outer cover Cover Gasket CLUTCH PVT SEALING AND DUCTING COMPONENTS Inner Cover Outer Cover Seal Clip CA He 6 8 A POLARIS CX DRIVE CLUTCH SPRING SPECIFICATIONS The drive clutch spring has two prima T NEUTRAL ry functions 1 To control clutch engagement 22 RPM The springs which have a 260 higher rate when the clutch is in neutral will increase clutch 249 engagement RPM 2 To control the rate at which the 22 drive belt moves upward in the drive clutch sheaves This is referred to as drive clutch upshift 180 There are other components which control upshift butthe spring is one of the primary components in insuring optimum performance It is very im portant that the spring is of the correct 120 design and is in good condition CAUTION Never shim a drive clutch spring to increase its compression 80 _ gt rate This may result in complete FU stacking of the coils and subsequent 60 clutch cover failure FORCE POUNDS 160 140 The drive clutch spring is one of the most critical components of the PVT 20 system Itis also one ofthe easiestto service Due to the severe stress the 2 5 2 25 2 00 spring is subject to during operation it CLUTCH FULL UPSHIFT ATV TRAVEL
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