Clutching (PVT) - the Polaris International Extranet
Contents
1. XP Models 12 Install the PVT outlet duct and align it with the inner PVT cover Install the push rivet and tighten the hose clamps to 12 16 in Ibs 1 4 1 8 Nm NOTE Be sure the rubber storage box shield is resting on top of the outlet duct as shown so it does not obstruct air flow 13 Replace the outer PVT cover seal 14 Reinstall outer PVT cover and secure with screws Torque screws to specification T Outer PVT Cover Screws 45 50 in Ibs 5 5 6 Nm 15 Reinstall the rear cab tail light bulbs and fasteners 16 Reinstall the lower left hand frame support and torque bolts to specification 7 10 Lower Left Hand Frame Support Bolts 36 ft Ibs 49 Nm 17 Install the left rear wheel and torque wheel nuts to specification T Wheel Nuts Steel 45 ft Ibs 61 Nm Aluminum 75 ft Ibs 102 Nm 18 Reinstall the seat lower the ATV start the engine and test the operation of the PVT system X2 TOURING Models 19 Install the PVT outlet duct and align it with the inner PVT cover Install the push rivet and tighten the hose clamps to 12 16 in Ibs 1 4 1 8 Nm 20 Replace the outer PVT cover seal 21 Reinstall outer PVT cover and secure with screws Torque screws to specification e T Outer PVT Cover Screws 45 50 in Ibs 5 5 6 Nm 22 Reinstall rear skid plate and 6 T40 Torx headed screws 23 Reinstall the rear fen2. Remove through bottom of frame iner A PVT Cover B 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT 5 Using care pull the outer PVT cover through the bottom of the frame NOTE Be sure to move the rear brake line out of the way upon removal to prevent from catching it with the outer PVT cover 6 Note the orientation of the drive belt so that it can be installed in the same direction 7 Loosen the driven clutch retaining bolt to allow the clutch sheaves to open ZE S Vee Loosen ms 8 Walk the belt out of the driven clutch and drive clutch and remove it from the vehicle 7 12 Belt Inspection 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Compare belt measurements with a new drive belt Replace if necessary 3 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See the Troubleshooting Chart at the end of this chapter for possible causes Belt Installation 1 Loop the belt over the drive clutch and over top of the driven clutch sheaves NOTE If reusing the drive belt be sure to reinstall the belt in the same d
3. It is also one of the easiest to service Due to the severe relaxation the spring is subject to during operation it should always be inspected for tolerance 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 NuMBER COLOR CODE aawer 125 NUMBER COLOR CODE paren 125 7041021 Plain 157 4 38 7041168 Green 177 3 05 7041022 Black 140 4 25 7043349 Red White 200 2 58 7041063 Purple 168 4 37 7043372 Red Blue 187 2 56 7041132 White 177 2 92 7043382 Red Green 177 2 63 7041157 Blue Green 177 2 53 7043500 Red Black 200 2 82 7 14 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT Shift Weights Shown below are the shift weights which have been designed for this 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 positioning and the effects they may have on belt to sheave cl
4. Removal Tool PN 2870341 IMPORTANT The clutch shaft has left hand threads Be sure to turn the Spider Removal Tool in a clockwise direction to remove Cover Bushing Inspection Replace the cover bushing if more 2870341 brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly Be sure to note the number and thickness of these washers To maintain proper clutch balance and belt to sheave clearance be sure to reinstall original quantity and thickness washers Moveable Sheave Bushing Inspection 4 Inspect the Teflon coating on the moveable sheave bushing d Teflon Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter Roller Pin and Thrust Washer Inspection 1 Inspect all 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 roll
5. a pin punch and hammer tap the spring pins out of the moveable sheave as shown 1 Clean the sheaves and inspect each of them for damage Inspect Sheaves non serviceable 8 Once the spring pins are removed turn the clutch over and remove the roller pins and outer clutch rollers as shown NOTE If either clutch sheave is damaged the entire driven clutch assembly must be replaced 2 Inspect the compression spring for cracks or other damage Compression Spring 3 If removed inspect the outer clutch rollers and roller pins for excessive wear or damage Replace as needed Roller Pin Outer Roller 7 25 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 4 Remove the E rings and thrust washers from each end of the spider assembly Remove and inspect the inner clutch rollers for excessive wear or damage Replace components as needed Use new E rings upon assembly Inner Roller 5 Inspect the flanged bearings in the clutch sheaves and cam helix If bearings are damaged or have an excessive amount of wear the entire component must be replaced NOTE The flanged bearings are not serviceable If either clutch sheave bearing requires replacement the entire driven clutch assembly must be replaced Refer to the Polaris Electronic Parts catalog for specific parts availability 7 26 Clutch Assembly Line up the X on the moveabl
6. 1 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Cover Bushing Removal 1 Install main adapter Item 8 on puller Removal Tool Nut C Ei Adapter Reducer EU Main Piston Pin Adapter 8 Puller 2 Install adapter reducer Item 9 3 From outside of clutch cover insert removal tool Item 3 into cover bushing 4 With inside of cover toward vise slide cover onto puller 5 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 6 Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free 7 Remove nut from puller rod and set aside 8 Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 1 Apply Loctite 609 evenly to bushing bore in cover 2 Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover 3 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 4 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 5 Turn clutch cover counterclockwise on puller rod until bushing is seated 6 Remove nut from puller rod Take installation tool and clutch cover off rod 7 22 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Clu
7. CLUTCHING PVT CHAPTER 7 CLUTCHING PVT SPECIAL TOOLS AND SUPPLIES eege Ne vinta ses Dee ee ae a See eee 7 2 TORQUE SPECIFICATIONS i oo eee t ot nae eoan dee eee ee bees 7 2 PVYTSY STEMOVERV EV 9 A dt dE 7 2 GENERALOPERATION toi ea e E 7 2 DRIVE CLUTCH OPERATION ceri minei eien Fa cece 7 2 SHIFT WEIGHT S cette reas ed Pe ea ta E area oe a DA at cleans E 7 3 DRIVEN CLUTCH OPERATION 0 000 002 cece eee 7 3 PVT BREAK IN DRIVE BELT CLUTCHES 0 000 000 0005 7 3 MAINTENANCE INSPECTION 7 3 OVERHEATING DIAGNOSE 7 4 PVTSYSTEM SERVICE ee de acon egen Eege Baws ow ele bee jes 7 5 PVT SEALING AND DUCTING COMPONENTS 2 000 00002005 7 5 PVT DISASSEMBLY XP MODELS 000 000 e eee eee eee 7 6 PVT DISASSEMBLY X2 TOURING MODEL SI 7 7 PVT ASSEMBLY ug 2 hein ty cated eet ees Latte eo ee a 7 9 DRIVE D EE 7 11 BEET REMOVAL gesit ier al Stal nb id Rode bee beatae bo A 7 11 BELT INSPECTION 00 a E nee Bk 7 12 BELT INSTALLATION eege el Pe es ened eee Ea 7 12 PVT BREAK IN DRIVE BELT CLUTCHES 0 0 0 0 000 7 13 DRIVE GLUTCH SERVICE vc re eee avian Gan it pales bos Aleta ewe Ge EE 7 14 SPRING SPECIFICATIONS 0 000 002 cece eee 7 14 SHIFT E Ee RE 7 15 EXPEODED VIEW yo sea ett eae Bee ie eas eee e Es a 7 15 CLUTCH DISASSEMBLY Ae EE EE e dee ENEE ER 7 16 SPIDER REMOVAL si tiroidea TS Eis ea Gee ee Sa a 7 16 ROLLER PIN AND THRUST WASHER INSPECTIO
8. Disassembly X2 TOURING Models Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fastener placement 1 Remove the driver s seat and rear fenders X2 or rear cab assembly TOURING X2 Models e Tilt the rear cargo box open and remove the seat e Remove the 8 push rivets retaining each rear fender RH Rear Fender TOURING Models e Remove the rear passenger seat e Remove the 12 push rivets and 4 bolts retaining the rear cab assembly Shown without Rear Cab handgrips for clarity 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 6 7 8 Remove the tail light bulbs from the tail lamps disconnect the tail light harnesses from the rear cab and remove the rear cab to allow access to the PVT system for disassembly Remove the rear skid plate outer PVT cover and drive belt Refer to Belt Removal X2 TOURING Models Loosen the clamps remove the push rivet and remove the PVT outlet duct from the inner PVT cover Inner PVT Cover Push Rivet Outlet Duct Clamps Remove the PVT outlet duct from the vehicle to allow for driven clutch removal Remove the duct through the bottom of the frame in the same manner as the outer PVT cover With the belt removed completely remove the retaining bolt and driven clutch Lo Po Install the Drive Clutch Holder PN 9314177 onto the drive
9. Install removal tool Item A B into center of sheave with A side toward sheave NOTE Use Bushing Tool PA 47336 8 Install nut C onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if 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 Drive Clutch Bushing Installation 1 Place main adapter Item 8 on puller Puller Tool A B Side A toward sheave Nut C Bushing Main Adapter 8 p Piston Pin Puller i B sse 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Set bushing in place on sheave 4 Insert installation puller tool Item A B with A side down into center of bushing NOTE Some models use Bushing Tool PA 47336 5 With towers pointing upward slide sheave bushing and tool onto puller rod 6 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 7 Turn sheave counterclockwise making sure bushing is drawn straight into bore Continue until bushing is seated 8 Remove nut from puller rod and set aside 9 Remove sheave from puller 10 Remove installation tool 7 2
10. N 7 17 BUTTON TO TOWER CLEARANCE INSPECTION 7 18 SHIFT WEIGHT INSPECTION 7 18 BEARING INSPECTION 0 0 0000 c cee eee 7 18 CLUTCH INSPECTION Seau see bas ais wh Sata diene oan te Se 7 19 MOVEABLE SHEAVE BUSHING INSPECTION 7 20 BUSHING SERVICE end eet esas TEE Mats A Seeds Saag eo i 7 20 GLUTCH ASSEMBLY sco fare pat a tte dh ea WED elk eer dE 7 23 DRIVEN GLUTCH SERVICE soso tig de eg ea SR ns ta od 7 24 CLUTCH DISASSEMBLY 0020 eesti eh a Peco ee erate oral 7 24 CLUTCH INSPECTION occ 7 25 CLUTCH ASSEMBLY cn ose ans tires nats ee Se a ead abled Mea erger 7 26 EXPLODED VIEW A ug ec ce edhe de wide Pea ae he dl 7 28 TROUBLESHOOTING 3er e Goa de Sea eng Dae A aad ee Sees 7 29 7 1 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Drive Clutch Puller Short PA 48595 Clutch Holding Wrench 9314177 Clutch Holding Fixture 2871358 A Drive Clutch Spider Removal and 2870341 Installation Tool Roller Pin Tool 2870910 Clutch Bushing Replacement 2871226 Tool Kit Piston Pin Puller 2870386 Clutch Compression Tool 8700220 Clutch Bushing Replacement 2871025 Tool Kit SPECIAL SUPPLIES PART NUMBER Loctite 242 Blue N A Loctite 609 Green N A RTV Silicone Sealer 8560054 TORQUE SPECIFICATIONS PVT System Fastener Torques ITEM TORQUE VALUE Dri
11. all shift weights using new lock nuts on the bolts WS A Use new lock nuts i 7 Reinstall clutch spring 8 Reinstall cover aligning X mark with other marks Torque cover bolts evenly to specification e T Cover Bolt Torque 100 in Ibs 11 Nm 7 23 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT DRIVEN CLUTCH SERVICE 5 Turn the compression tool handle counter clockwise to relieve spring pressure and allow the cam helix to move Clutch Disassembly out from the moveable sheave 1 Remove driven clutch from the transmission input shaft see PVT Disassembly 2 It is important to mark the position of the cam helix and sheave before disassembly or use the X marks on the components for reference This will aid in reassembly and helps maintain clutch balance after reassembly 6 Remove the cam helix spider and compression spring from the clutch 3 Place the driven clutch into the Clutch Compression Tool PU 50518 Spin the tool down until it touches the cam helix Driven Clutch Compression Tool PU 50518 4 Using a T25 Torx driver remove the four screws that secure the cam helix assembly 7 24 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 7 In order to disassemble the clutch sheaves the roller pins Clutch Inspection must be removed Using
12. clutch Drive Clutch Holder 9314177 7 Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction NOTE The drive clutch retaining bolt has left hand threads Turn the bolt clockwise to remove it 8 Insert the Drive Clutch Puller PA 48595 into the drive clutch and use it to remove the clutch from the shaft AS NA w D _g Ea H gt eg PA 48595 Drive Clutch Puller PA 48595 Remove the drive clutch through the bottom of the frame 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 10 Remove the 10 screws that retain the inner PVT cover to the transmission case and remove the cover Or Inner 4 PVT oe P 11 Remove the old silicone material from the inner PVT cover and transmission case using a wire brush Clean both surfaces thoroughly in preparation for assembly PVT Assembly 1 Inspect the inner PVT cover Replace if cracked or damaged The mating surface must be clean to ensure adhesion of new silicone sealant Be sure to flame treat the inner PVT cover prior to applying silicone to ensure good adhesion Pass the flame of a propane torch back and forth quickly over the area where the silicone is to be applied 2 3 inches from the flame tip is recommended Do not hold the torch too close to the surface Keep the torch moving to prevent damage Apply RTV silicone sealant to the outsi
13. de edge of the inner PVT cover to ensure a water tight fit between the cover and the transmission Inner PVT Cover Apply Bead of RTV Silicone 4 Install the cover and torque the inner PVT cover screws to specification Inner PVT Cover Screws 6 8 ft Ibs 8 11 Nm 5 Wipe away any excess silicone sealant 6 Clean end of taper on crankshaft and the taper bore inside drive clutch using a tapered reamer 7 Install the drive clutch bushing washer lock washer and the left hand threaded retaining bolt Torque retaining bolt to specification Drive Clutch Retaining Bolt 47 ft Ibs 64 Nm 8 Clean the splines on the transmission input shaft and apply a light film of grease to the splines on the shaft 9 Install the driven clutch thrust washer flat washers and retaining bolt in the order shown Flat Washer 190 A a e PA Flat Washer 160 Thrust Washer 060 10 Install drive belt noting direction of rotation if the belt is being reused Refer to Belt Installation 11 Torque the driven clutch retaining bolt to specification e T Driven Clutch Retaining Bolt 37 ft Ibs 50 Nm NOTE While tightening the retaining bolt stop and rotate the driven clutch counter clockwise a few times to prevent the belt from binding in the clutch 7 9 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT
14. ders X2 or rear cab TOURING tail light bulbs and fasteners 24 Reinstall the seat s start the engine and test the operation of the PVT system 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT DRIVE BELT 8 Belt Removal XP Models 1 Position the vehicle on a level surface and place the transmission in Park 9 2 Elevate and safely support the rear of the vehicle 3 Remove the left rear wheel from the vehicle 4 Remove the 4 bolts retaining the lower left hand frame support and remove it from the frame 1 5 Remove the seat SS 6 Remove the 11 screws retaining the PVT cover 3 Remove through LH Wheel Well 4 Outer PVT Cover Inner PVT Cover 7 Using care pull the outer PVT cover out the left hand wheel well Note the orientation of the drive belt so that it can be installed in the same direction Loosen the driven clutch retaining bolt to allow the clutch sheaves to open 10 Walk the belt out of the driven clutch and drive clutch and remove it from the vehicle Belt Removal X2 TOURING Models Position the vehicle on a level surface and place the transmission in Park Remove the 6 T40 Torx headed screws retaining the rear skid plate and remove the skid plate from under the vehicle Remove the driver s seat Remove the 11 screws retaining the PVT cover PVT Outlet Outer Te PVT Cover
15. e sheave with the X on the stationary sheave and place the sheaves together y Align X Marks Install the outer clutch roller and roller pin on both sides of the moveable sheave Press the roller pin into the moveable sheave on each side with the flat side of the roller pin facing down as shown Ee Sae Dom d 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 4 Install new spring pins to secure the roller pins in the 7 Install the cam helix on top of the spider Align the X moveable sheave Tap the spring pins in until they are flush mark on the cam helix with the X mark on the moveable with sheave surface sheave 8 Place the clutch assembly onto the Clutch Compression Tool PU 50518 Turn the compression tool handle clockwise to overcome spring pressure and force the cam helix into the moveable sheave Align X Marks E cam Het E Ring E Ring Inner Roller Inner Roller NOTE Be sure the X mark on the cam helix is aligned with the X mark on the moveable sheave 5 Install the inner clutch rollers thrust washers and E rings gt onto the spider if previously disassembled l 9 Replace the 4 T25 Torx screws thread locking agent applied or apply Loctite 242 to the existing screws 10 Use a T25 Torx driver to install the four screws and torque them to specification Washer plas Washer 6 In
16. earance clutch balance and shifting pattern PN 5632394 PN 5632216 PN 5632418 Exploded View Bushing Spring Buttons Washers Roller Bearing 2 One Way gt E Q ke Flat Bearing i Bolts Washer Cover Bearing Limiter Washers 7 15 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Clutch Disassembly 5 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch if worn or damaged 1 Using a permanent marker mark the cover spider and moveable and stationary sheaves for reference as the cast in X s may not have been in alignment before disassembly 6 Remove and inspect the clutch spring See Drive Clutch Spring Specifications for spring inspection 2 Mark the stationary sheave and clutch shaft to verify the Spider Removal shaft has not turned in the sheave after tightening the spider during clutch assembly 1 Remove the limiter spacer from the shaft 3 Remove cover bolts evenly in a cross pattern and remove 2 Install clutch in holding fixture PN 2871358 A cover plate NOTE This updated holding fixture is required to fit 4 Inspect cover bushing A The outer cover bushing is HIE Dey ie ye Clune i Wit a Cure Eb design manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing 3 Loosen the spider clockwise using Clutch Spider
17. er 5 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period 7 13 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT DRIVE CLUTCH SERVICE Spring Specifications The drive clutch spring has two primary functions NEUTRAL FULL S ch 300 1 To control clutch engagement RPM The springs m AV TRAVEL bet which have a higher rate when the clutch is in og9 amp SCH a neutral will increase clutch engagement RPM z 2603 i i S A 2 To control the rate at which the drive belt moves 249 w y Bee upward in the drive clutch sheaves This is referred g A dE to as drive clutch upshift 290 X 7 Tel eae Y F 200 4 Pa There are other components which control upshift but the Pd e spring is one of the primary components in insuring 180 4 zt EEN optimum performance It is very important that the spring a0 At Ai ite GER Sch Y N is of the correct design and is in good condition ees 140 atie Plan AA CAUTION 120 Ze Blue Green 7041157 100 a Sii Never shim a drive clutch spring to increase its 701022 compression rate This may result in complete stacking of the coils and subsequent clutch 60 cover failure 2 25 2 00 1 75 1 50 1 25 1 19 COMPRESSED SPRING LENGTH INCHES The drive clutch spring is one of the most critical components of the PYT system
18. ers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all 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 7 17 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT Button To Tower Clearance Inspection 1 2 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface of towers See Spider Removal procedure Button to Tower Clearance 000 005 Inspect sheave surfaces Replace the entire clutch if worn damaged or cracked Shift Weight Inspection 7 18 The clutch assembly is a precisely balanced A WARNING unit Never replace parts with used parts from another clutch assembly If clutch is not disassembled inspect as shown using a clutch holding tool to compress the moveable sheave The contact surface of the weight should be smooth and free of dents or gall marks Remove shift weight bolts and weights Inspect the contact surface of the weight The surface should be smooth and free of dents or gall marks Inspect the 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
19. h Bushing Replacement Tool Kit PN 2871226 Item Qty Part Description Part P 90 Drive Driven Clutch ie l Bushing Install Tool SE Drive Clutch Cover Bushing Removal ae i Installation Tool all outer clutches P 90 Driven Clutch Cover 9 i Bushing Removal Tool SE 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller 5020633 Adapter NOTE Bushings are installed at the factory using Loctite 609 In order to 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 installing new bushing 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves during the removal process Moveable Sheave Bushing Removal 1 Remove clutch as outlined previously in this chapter 2 Install handle end of the Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads Piston Pin Puller PN 2870386 3 Remove nut from puller rod and set aside Piston Pin Puller PN 2870386 Main Puller Adaptor 8 PN 5020632 4 5 kiya H k KM di Adapter 10 PistonPin Puller Main Adapter D 6 With towers pointing toward the vise slide sheave onto puller rod 7
20. hen exposed to low ambient temperatures Warm engine at least 5 min then with transmission in neutral 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 Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Stuck in mud or snow Shift the transmission to Low carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Shift the transmission to neutral Using the throttle vary the engine rom 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 Polaris dealer Shift transmission to Low during loading of the vehicle to prevent belt b
21. hrust Washer Thickness or damaged 7 Standard 030 76 mm Service Limit 025 64 mm Ji E In mm 3 Remove the moveable clutch sheave gt PTFE Washer Thickness Standard 030 76 mm Service Limit 025 64 mm 4 Lift bearing 3 and thrust washer 4 off shaft Replace as an assembly if worn damaged or if problems were noted Size of bearing may differ from what is shown o 7 19 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Moveable Sheave Bushing Inspection Inspect the Teflon coating arrow on the moveable sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 7 20 Bushing Service IMPORTANT Special Tools Required EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS BushingRemoval Tool 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool Kit 2871226 1 Piston Pin Puller 2870386 Clutc
22. ht harnesses from the rear cab and remove the rear cab to allow access to the PVT system for disassembly 4 Remove the left rear wheel lower LH frame support outer PVT cover and drive belt Refer to Belt Removal XP Models 5 Loosen the clamps remove the push rivet and remove the PVT outlet duct from the inner PVT cover Remove the duct from the vehicle _ Push Rivet __ Outlet Duct Clamps 7 6 With the belt removed completely remove the retaining bolt and driven clutch Lo Install the Drive Clutch Holder PN 9314177 onto the drive clutch Drive Clutch Holder 9314177 Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction NOTE The drive clutch retaining bolt has left hand threads Turn the bolt clockwise to remove it 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 9 Insert the Drive Clutch Puller PA 48595 into the drive clutch and use it to remove the clutch from the shaft f y H l ay r e hc Drive Clutch Puller PA 48595 10 If removing the inner PVT cover continue with this procedure 11 Remove the 10 screws that retain the inner PVT cover to the transmission case and remove the cover 12 Remove the old silicone material from the inner PVT cover and transmission case using a wire brush Clean both surfaces thoroughly in preparation for assembly PVT
23. irection as it was removed 2 Torque the driven clutch retaining bolt to specification E T Driven Clutch Retaining Bolt 37 ft Ibs 50 Nm NOTE While tightening the retaining bolt stop and rotate the driven clutch counter clockwise a few times to prevent the belt from binding in the clutch 3 Replace the outer PVT cover seal 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT 4 Reinstall outer PVT cover and secure with screws Torque screws to specification Outer PVT Cover Screws 45 50 in Ibs 5 5 6 Nm XP Models 5 Reinstall the lower left hand frame support and torque bolts to specification Lower Left Hand Frame Support Bolts 36 ft Ibs 49 Nm 6 Install rear wheel and torque wheel nuts to specification E T Wheel Nuts Steel 45 ft Ibs 61 Nm Aluminum 75 ft Ibs 102 Nm 7 Install the seat lower the ATV start the engine and test the operation of the PVT system X2 TOURING Models 8 Reinstall the rear skid plate and the 6 T40 Torx headed screws 9 Install the seat start the engine and test the operation of the PVT system PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour break in period as recommended see Chapt
24. n of existing components must be the primary objective when troubleshooting and tuning Drive Clutch Operation Drive clutches primarily sense engine RPM The two major components which control its shifting function are the shift weights and the coil spring Whenever engine RPM is increased centrifugal force is created causing the shift weights to push against rollers on the moveable sheave which is held open by coil spring preload When this force becomes higher than the preload in the spring the outer sheave moves inward and contacts the drive belt This motion pinches the drive belt between the spinning sheaves and causes it to rotate which in turn rotates the driven clutch At lower RPM the drive belt rotates low in the drive clutch sheaves As engine RPM increases centrifugal force causes the drive belt to be forced upward on drive clutch sheaves 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Shift Weights 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 positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern Driven Clutch Operation Driven clutches primarily sense torque opening and closing according to the forces applied to it from the drive belt and the
25. nsure a longer life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour break in period as recommended see Chapter 5 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Maintenance Inspection Under normal use the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information e Belt Inspection e Drive and Driven Clutch Buttons and Bushings e Drive Clutch Shift Weights and Pins e Drive Clutch Spider Rollers and Roller Pins e Drive and Driven Clutch Springs e Sheave Faces clean and inspect for wear e PVT System Sealing Refer to appropriate illustrations 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 duct is located at a 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 PVT co
26. ring to determine problem area Replace belt Inspect movable sheave for excessive bushing clearance Replace the clutch Engine RPM above specified operating range Incorrect drive clutch spring too high spring rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Clutch sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive clutch engagement Drive belt worn too narrow Excessive belt sheave clearance with new belt Replace belt Perform belt sheave clearance adjustment with shim washers beneath spider Drive belt turns over Wrong belt for application Replace with correct belt Belt burnt thin spots Abuse continued throttle application when vehicle is stationary excess load Dragging brake Slow easy clutch engagement Caution operator to operate machine within guidelines Vehicle operated with parking brake on Inspect brake system Fast effective use of throttle for efficient engagement 7 29 9923067 2011 Sportsman 850 Se
27. rvice Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Troubleshooting Continued Situation Probable Cause Remedy PVT cover overheating melting Plugged air intake or outlet Belt slippage due to water oil grease etc rubbing on cover High vs low range Clear obstruction Inspect system Clean repair or replace as necessary Seal PVT system ducts Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner s Safety and Maintenance Manual Water ingestion Cover seal or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt worn out Replace belt erratic or stabby Drive clutch bushings stick Belt slippage Water ingestion Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean Belt worn or separated thin spots loose belt Replace belt E Broken or worn clutch components cover hitting Inspect and repair as necessary clutches Thin spots on belt worn belt Replace belt Refer to belt burnt troubleshooting and Engagement instruct operator Inspect and repair clutches 7 30 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc
28. stall the compression spring and spider assembly into the moveable sheave Align the X mark on the spider with the X mark on the moveable sheave as shown T25 Torx Screws 47 in Ibs 5 3 Nm 7 27 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT Exploded View Roller Pin Outer Roller Inner Roller Stationary Sheave non serviceable Compression Spring Moveable Sheave non serviceable Cam Helix Torx Screws 47 in lbs 5 3 Nm 7 28 9923067 2011 Sportsman 850 Service Manual O Copyright 2010 Polaris Sales Inc CLUTCHING PVT TROUBLESHOOTING Situation Engine RPM below specified operating range although engine is properly tuned Probable Cause Wrong or broken drive clutch spring Drive clutch shift weight too heavy Driven clutch spring broken or installed in wrong helix location Remedy Replace with recommended spring Install correct shift weight kit to match engine application Replace spring refer to proper installation location Erratic engine operating RPM during acceleration or load variations Drive clutch binding Belt worn unevenly thin burnt spots Driven clutch malfunction Sheave face grooved A Disassemble drive clutch inspect shift weights for wear and free operation B Clean and polish stationary shaft hub reassemble clutch without sp
29. tch Assembly NOTE It is important that the same number and thickness of washers are reinstalled beneath the spider during assembly The Teflon bushings are self lubricating AA CAUTION Do not apply oil or grease to the bushings Reassemble the drive clutch in the sequence provided below Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install moveable sheave onto fixed sheave 2 Install spider spacers Use same quantity and thickness as were removed Spacer washers 3 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier on spider aligns with X or the marks that were made earlier in moveable sheave 4 Torque the spider counter clockwise to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave IMPORTANT The clutch shaft has left hand threads Be sure to turn the Spider Removal Tool in a counter clockwise direction to reinstall E T Spider Torque 200 ft Ibs 271 Nm 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 5 Install the limiter spacer over the shaft and on top of spider Inst
30. transmission input shaft If the torque resistance at the trans mission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called upshifting Should the throttle setting remain the same and the vehicle is subjected to a heavier load the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch This action which decreases the driven clutch speed is called backshifting 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 At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will e
31. urning Poor engine performance Fouled plugs foreign material in gas tank fuel lines or carburetor Contact you dealer for further service information GENERAL RANGE OPERATION GUIDELINES Low Heavy pulling basic operational speeds less than 7 MPH riding through rough terrain swamps mountains ect low ground speeds High High ground speeds speeds above 7 MPH IMPORTANT Using High Gear when pulling heavy loads operating on hilly terrain or in wet muddy conditions will increase the chance of drive belt damage 7 4 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT PVT SYSTEM SERVICE PVT Sealing and Ducting Components Cover Screws Outer PVT Cover Q Outer Seal Clamps Os Air Inlet Duct Drain Plu Ds yr O d De GA Boot O Ring Screws Boot Outlet Duct Es e E Q Inner Ni 3 l PVT Cover x d AS i K Boot X2 TOURING N MODELS g 7 5 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT PVT Disassembly XP Models Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fastener placement 1 Remove the seat 2 Remove the 10 push rivets and 4 Torx headed screws retaining the rear cab assembly Rear Cab Assembly 3 Remove the tail light bulbs from the tail lamps disconnect the tail lig
32. ve Clutch Spider 200 ft lbs 271 Nm 47 ft lbs 64 Nm Drive Clutch Retaining Bolt Left Hand Thread Driven Clutch Retaining Bolt 37 ft lbs 50 Nm Drive Clutch Cover Bolts 100 in lbs 11 Nm Inner PVT Cover Screws 6 8 ft Ibs 8 11 Nm Outer PVT Cover Screws 45 50 in lbs 5 5 6 Nm Drive Clutch Weight Pins 15 25 in lbs 2 3 Nm 7 2 PVT SYSTEM OVERVIEW General Operation A WARNING All PVT maintenance or repairs should be performed by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized special tools and service procedures The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During the development of a Polaris ATV the PVT system is matched first to the engine power curve then to average riding conditions and the vehicle s intended usage Therefore modifications or variations of components at random are never recommended Proper clutch setup and careful inspectio
33. ver must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area This is especially critical on units subjected to frequent water forging 7 3 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Overheating Diagnosis During routine maintenance or whenever PVT system overheating is evident it s important to check the inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures The vehicle should be operated in Low when plowing or pulling 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 vehicle into a truck or tall trailer when in high range Shift transmission to Low during loading of the vehicle to prevent belt burning Starting out going up a steep incline from a stopped position When starting out on an incline use Low or dismount the vehicle after first applying the park brake and perform the K turn Driving at low RPM or low ground speed at approximately 3 7 MPH Drive at higher speed or use Low The use of Low is highly recommended for cooler PVT operating temperatures and longer component life Insufficient engine warm up w
34. weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thrust Washer Inspection Bearing Inspection 1 Rotate the clutch bearing in both clockwise and counter clockwise directions The one way bearing should rotate counter clockwise when viewed from cover plate side with only a slight amount of drag When rotated clockwise the one way bearing should lock to the shaft without slipping Verify there is no binding or rough spots If problems are noted continue with disassembly 9923067 2011 Sportsman 850 Service Manual Copyright 2010 Polaris Sales Inc CLUTCHING PVT Clutch Inspection 5 Inspect surface of shaft for pitting grooves or damage i i Measure the outside diameter and compare to NOTE Remove cover spring and spider following specifications Replace the drive clutch assembly if shaft is instructions for drive clutch removal then proceed worn or damaged as follows 1 Remove the moveable sheave spacer sleeve 1 and the thrust washer 2 Visually inspect the washer for damage 2 Measure the thickness and compare to specification Replace if worn or damaged li y lt n mm Shaft Diameter Standard 1 3745 1 375 34 91 34 93 mm Service Limit 1 373 34 87 mm l y Gm In mm 6 Visually inspect PTFE thrust washer for damage Measure the thickness and compare to specification Replace if worn T
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