9918066 2002-2003 Sportsman 600/700 Service Manual Chapter
Contents
1. CGO POLARIS CHAPTER 6 PVT SYSTEM Drive Clutch Exploded View 6 2 PVT Sealing and Ducting Components 6 2 EBS System Exploded View 6 3 Special Tools Supplies amp Torques 6 4 PVT Operation Overview 6 4 PVT Maintenance Inspection Drying 6 5 PVT Overheating Diagnosis 6 6 PVT Disassembly 6 7 PVT Assembly Inspection 6 8 Drive Clutch Spring Specifications 6 9 shift Weights Inspection 6 10 6 11 Drive Clutch Disassembly Inspection 6 11 6 13 Drive Clutch Reassembly 6 13 6 14 Drive Belt Removal Inspection 6 14 6 15 Drive Belt Installation 6 16 Clutch Alignment Offset 6 16 6 17 Drive One way Clutch Inspection 6 17 6 18 Driven One way Clutch Inspection 6 18 6 20 Drive Clutch Bushing Service 6 20 6 21 Driven Clutch Bushing Service 6 22 6 23 Troubleshooting 6 24 6 25 CLUTCH 6 1 CLUTCH 0 DRIVE CLUTCH EXPLODED VIEW Mark with permanent marker before disassembly t TO 6 One way clutch Boot Duct Clutch Cover Seal Inner Cover Seal Seal Retainer Bracket Clutch Cover 62 CLUTCH ENGINE BRAKING SYSTEM EBS2. EBS DRIVE BUSHING SERVICE EBS CLUTCH BUSHING REMOVAL AND INSTALLATION Use Tool Kit PN 2201379 The contents of this kit include Item Qty Part Description Part No A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing 5132028 Removal Tool 1 Instructions 9915111 Also required Clutch Bushing Replacement Tool Kit PN 2871226 ATV Clutch Kit or PN 2871025 For all clutches Piston Pin Puller PN 2870386 REMOVAL AND INSTALLATION INSTRUCTIONS 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 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 lightly grease puller threads 3 Remove nut from puller rod and set aside 4 Install puller adapter Item 10 from kit PN 2871226 5 Install main adapter Item D onto puller Puller Tool A B Side A toward sheave _ Nut C Puller Adapter 10 Piston Pin P uller CGO POLARIS 6 7 9 10 11 With towers pointing toward the vise slide sheave onto puller rod Install removal tool Item A B into center of Sheave with A sid
3. 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 atthe 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 MAINTENANCE INSPECTION Under normal operation 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 1 Drive to Driven Clutch Offset Belt Width See Page 6 16 6 18 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Cl
4. 5630513 PN 5630710 PN 5630711 44 gr 50 5 gr 46 gr 479 5631214 5631215 610 SHIFT WEIGHT INSPECTION 1 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 Broken Worn Good 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 weight is usually caused by a damaged or stuck roller in the spider assembly See roller inspection Page 6 12 A WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly All PVT maintenance or repairs should be performed only 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 system it is absolutely essential that no attempt at disassembly or repair be made without factory authorized special tools and service procedures CGO POLARIS CLUTCH BUTTON TO TOWER CLEARANCE INSPECTION 1 Inspect for any clearance between spider button to tower If clearance exists replace all buttons and inspect surface o
5. 6 Install limiter nut on top of spider using the Clutch S pider Nut Socket PN 2870338 Torque to 15 ft los Reinstall shift weights using new lock nuts on the bolts 7 Reinstall clutch spring e 5 EA Rotation a E F i Nut on trailing side 6 14 XO 8 Reinstall cover aligning X mark with other marks Torque cover bolts evenly to specification Spider Torque 200 ft Ibs 271 Nm Cover Screw Torque 90 in Ibs 10 4 Nm 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 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 CGO POLARIS NOTE When reinstalling the belt with the drive clutch and driven clutch already removed follow these steps Install the driven clutch Install the belt onto the driven clutch Loop the drive clutch through the belt Install the drive clutch onto the crankshaft Measure belt width and replace if worn Generally belts should be replaced if clutches can no longer be adjusted to provide proper belt deflection The top edges have been trimmed on some drive belts It willbe necessary to pro
6. held at the full position for more than 10 seconds PVT seals should be inspected for damage if repeated leaking occurs Clutch malfunction Inspection repair of clutch components should be performed by a certified Polaris MSD techinician Slow and easy clutch engagement 6 _ PVT DISASSEMBLY NOTE Some fasteners and procedures will vary Refer to the appropriate parts manual for proper fasteners and fastener placement 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 Remove outer cover screws Refer to Page 6 2 5 Mark the drive belt direction of rotation and remove drive belt See Page 6 16 for drive belt removal 6 Remove drive clutch retaining bolt and remove drive clutch using puller Drive Clutch Puller PN 2870506 Clutch Holding Wrench PN 9314177 7 Remove driven clutch retaining bolt and driven clutch Use puller if necessary POLARIS CLUTCH Driven Clutch Puller PN 2870913 8 Remove driven clutch offset spacers from the transmission input shaft NOTE Remember to keep Spacers in order for proper clutch offset on reassembly Keep Spacers In Order Inner cover Retainer Seal 10 Remove inner cover retaining bolts at rear of cover 11 Remove cover along with foam seal on back of cover or shaft 6
7. onto puller rod and hand tighten against installation tool 7 Turn clutch sheave counterclockwise making Sure bushing is drawn straight into bore Continue until bushing is seated CGO POLARIS CLUTCH 8 Remove nut C left hand thread from puller rod and set aside 9 Remove installation tool and clutch sheave from puller 6 23 CLUTCH TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM Wrong or broken drive clutch spring Replace with recommended spring below specified Operating range Drive clutch shift weight too heavy Install correct shift weight kit to match engine application although engine is properly Driven clutch spring broken or installed Replace spring refer to proper installation location tuned wrong Erratic engine Drive clutch binding a Disassemble drive clutch inspect shift weights for wear Operating RPM and free operation during accelera b Clean and polish stationary shaft hub reassemble clutch tion or load vari without spring to determine problem area ations Belt worn unevenly thin burnt spots Replace belt Driven clutch malfunction a Replace ramp buttons b Inspect movable sheave for excessive bushing clearance replace Sheave face grooved Replace the clutch Engine RPM Incorrect drive clutch spring too high Install correct recommended spring above specified Spring rate Operating range Drive clutch shift weights i
8. 25 1 19 Spring to increase its compression rate This may result in complete Stacking of the coils and subsequent clutch component failure COMPRESSED SPRING LENGTH INCHES Measuring Spring Length With the spring resting on a flat surface measure its free length from the outer coll 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 DESCRIPTION NUMBER CODE DIAMETER 1 1287 NUMBER 157 ase vonr 5 foose Toms wms Je _ ar Jeo ons _ Toms Buren L177 25 Siverue _ POLARIS 6 9 CLUTCH re SHIFT WEIGHTS Shown below are optional shift weights which may be used in the PVT system These shift weights have many different 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 the effects they have on belt to sheave clearance clutch balance engagement and shifting characteristics PN 5630418 PN 5630279 PN 5630095 PN 5630509 50 gr 43 gr 53 gr 39 OF H 1 5630709
9. 7 CLUTCH PVT ASSEMBLY INSPECTION 1 InspectPVT inner cover to engine seal Replace if cracked or damaged Align the alignment mark on the cover with the mark on the engine seal Seal this edge to cover on engine side 2 Place a new seal on transmission input shaft 3 Apply RTV silicone sealant to 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 4 Reinstall cover and tighten rear cover bolts just enough to hold it in place 5 of inner cover seal A to engine Install seal retainer plate and tighten screws securely 6 Torque rear inner cover bolts B to specification pe Seal outer edge to cover with RTV silicone sealant 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 7 Install clutch offset spacer s on transmission input shaft 8 Clean splines inside driven clutch and on the transmission input shaft 9 Apply a light film of grease to the splines on the Shaft 10 Install the driven clutch washer lock washer and retaining bolt Torque to specification 11 Clean end of taper on crankshaft and the taper bore inside drive clutch 12 Install drive clutch and torque retaining bolt to Specification 13 Re
10. EXPLODED VIEW a Coil Spring over Bushing Bolts Lock Washers Ae Drive Clutch Assembly Retaining ae i Ring a Ramp M 2 25 PTFE p One Way Washer Clutch Drive Ramp Bushing Shift Weights 200 Ft Lbs 271 Nm Torque to gs 3 D Spider Lock Nut CGO POLARIS Brass R oller Bushing Assembly Washer Compression Spring Screw SPs Roller EE Hee Clutch 2 Driven wee Drive Belt PTFE Washer Retaining P Ring Spacer Sleeve a Driven Clutch Assembly 6 3 CLUTCH SPECIAL SERVICE TOOLS AND SUPPLIES TOOL DESCRIPTION Clutch Puller 2870506 Clutch Holding 9314177 Wrench Clutch Holding Fixture Spider Nut Socket 2870338 Drive Clutch 2870341 S pider Removal and Install Tool Driven Clutch Puller Roller Pin Tool 2870910 Clutch Bushing 2871226 Replacement Kit Piston Pin Puller 2870386 EBS Clutch 2872292 Alignment Tool EBS Bushing Replacement Kit Clutch Compression Tool Clutch Bushing 2871025 Replacement Tool Kit SPECIAL SUPPLIES PART NUMBER 2871358 2870913 2201379 8700220 PART NUMBER Loctite 680 2870584 RTV Silicone Sealer 2870661 Loctite Gasket Remover 2870601 PVT SYSTEM FASTENER TORQUES Drive Clutch Retaining Bolt 40 ft lbs 54 Nm Driven Clutch Retain
11. Holding Fixture PN 2871358 Spider Removal Tool PN 2870341 It is important that the same number and To maintain proper clutch balance and belt to sheave clearance be Sure to reinstall original quantity and thickness washers CGO POLARIS CLUTCH Moveable Sheave Bushing Inspection button is positioned toward the solid roller pin Itis recommended to switch all buttons to the rubber version during service if needed 2 Inspect the Teflon coating on the moveable Sheave bushing Moveable Sheave Bushing Inspection DRIVE CLUTCH REASSEMBLY Replace the cover bushing if more brass than Teflon is visible on the bushing NOTE It is important that the same number and Refer to bushing replacement in this thickness of washers are reinstalled beneath the chapter Spider during assembly The Teflon bushings are Self lubricating Do not apply oil or grease to the bushings Roller Pin and Thrust Washer In ion ore ang MMe 1 Reassemble drive clutch in the following 3 Inspect all rollers bushings and roller pins by sequence Be sure X or the marks thatwere pulling a flat metal rod across the roller Turn roller made earlier are aligned during each phase of with your finger If you notice resistance galling assembly or flat spots replace rollers pins and thrust a X orthe marks that were made earlier on washers in sets of three Also inspect to see if cover roller a
12. at approximately 3 7 MPH Range is highly recommended for cooler PVT operating tem peratures and longer component life Insufficient warm up of ATVs exposed to Warm engine at least 5 min then with transmission in neutral low ambient temperatures advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Fast effective use of the throttle for efficient engagement Continuous operation at the point of engagement initial vehicle movement increases PVT temperatures and component wear Towing P ushing at low RPM low ground Use Low Range only speed Plowing snow dirt etc utility use Use Low Range only 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 overturn Climbing over large objects from a Shift the transmission to Low Range carefully use fast stopped position aggressive throttle application to engage clutch Warning 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 rom from idle to 3 4 throttle Engage transmission in the lowest possible range and test for belt slippage Repeat several times as required During this procedure the throttle should not be
13. ch Center Distance 10 1 05 254 2 5 1 3mm Belt Nominal Length 40 875 3 16 103 8 cm 48 cm 6 15 CLUTCH 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 beltso partnumber Is easily read CLUTCH ALIGNMENT 1 Remove belt and install the Clutch Offset Alignment Tool PN 2872292 as shown Offset Alignment Tool PN 2872292 EBS 1 8 0 1 16 3 2mm 0 1 6 mm 6 16 2 With tool touching rear of driven clutch inner sheave the distance at point A should be 1 8 NOTE 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 7 6 8 4 Remove PVT inner cover 5 Loosen all engine mounts Move front of engine to the rightor leftslightly until alignmentis correct 6 Tighten engine mounts and verify alignment is correct 7 Measure belt deflection and measure offset both above and below shaft centerlines Adjust if necessary Center line Measure offset above and below centerline NOTE On some models minor adjustments can be made by adding shims between the frame and front lower left engine mount to increase
14. e toward sheave 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 Turn sheave counterclockwise on puller rod until it comes free Lift sheave off puller Remove nut from puller rod and set aside P ull bushing removal tool and adapter from puller rod Remove bushing from tool and discard EBS Drive Moveable Bushing Installation 1 9 10 Place main adapter Item 8 on puller Puller Tool A B Side A toward sheave Bushing A _ Pin Main Adapter 8 Puller EBS Drive Clutch Moveable Sheave Bushing Installation Apply Loctite 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 sheave 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 Remove installation tool CGO POLARIS CLUTCH EBS Drive Clutch Cover Bushing Removal 1 Install main adapter Item 8 on puller Adapter Reduce
15. e 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 againstrollers 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 DRIVEN CLUTCH OPERATION Driven clutches primarily sense torque opening and closing according to the forces applied to it from the drive belt and the transmission input shaft If the torque resistance at the transmission input shaft is greater than the load from the drive belt the drive belt 5 kept at the outer diameter of the driven clutch sheaves CGO POLARIS DRIVEN CLUTCH OPERATION CONT D 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
16. e if necessary Rollers ROLLER PIN DISASSEMBLY New roller retaining bolts have a dry locking agent applied to the threads Before attempting to remove the roller pins heat the threaded area lightly with a propane torch Wear heat resistant gloves during this procedure Use a high quality hexagonal wrench in good condition to avoid screw damage A small amount of valve grinding compound can be applied to the tip of the hex wrench to ensure a tight fit Always use new bolts if they are removed for inspection Apply Loctite 680 retaining compound sparingly to the tapered head portion of the roller retaining screws Do not allow locking agent to contact the inside of the rollers Do not lubricate the roller or roller pin Heat Area Lightly Roller Apply Loctite 680 To Tapered Portion Of Screw Dry Locking Agent Applied To New Screws 6 19 CLUTCH DRIVEN CLUTCH DISASSEMBLY INSPECTION CONT D 7 Inspect moveable sheave bushing for wear Inspect BOTH sheaves for signs of wear grooving or cracking Clean surfaces with a 3M pad if needed Moveable Sheave Bushing Inspection Replace the bushing if more brass than Teflon is visible on the surface of the bushing 8 Check for movement of the shaft in the one way clutch Ifthe shaftcan be moved laterally or ifthe One way clutch does not function properly as described in Step 1 and 2 on Page 6 18 replace driven clutch assembly 6 20
17. f towers Removal Page 6 12 See Spider Button to Tower Clearance 000 001 2 Inspect sheave surfaces Replace the entire clutch as an assembly if worn damaged or cracked DRIVE CLUTCH DISASSEMBLY 1 Using a permanent marker mark the cover Spider and moveable and stationary sheaves for reference as the previous X s may not have been in alignment before disassembly 6 11 CLUTCH DRIVE CLUTCH DISASSEMBLY CONT D 2 Remove cover bolts evenly in across pattern and remove cover plate 3 Inspect cover bushing A The outer cover bushing is manufactured with a Teflon coating Wear is determined by the amount of Teflon remaining on the bushing Cover Bushing inspection Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replace ment in this chapter 4 Inspect area on shaft where bushing rides for wear galling nicks orscratches Replace clutch assembly if worn or damaged 5 Remove and inspect spring See Page 6 9 6 12 NOTE thickness of washers are reinstalled beneath the Spider during assembly Be sure to note the number and thickness of these washers SPIDER REMOVAL 1 Remove the limiter nut using the Clutch Spider Nut Socket PN 2870338 Install clutch in holding fixture and loosen the spider counterclockwise using Clutch Spider Install Tool PN 2870341 Clutch
18. he thickness and compare to Specification Replace if worn or damaged Brass Washer Thickness Standard 030 76mm Service Limit 025 64mm 2 Lift one way clutch off shaft Replace as an assembly if worn damaged or if problems were noted CGO POLARIS 6 17 CLUTCH ONE WAY CLUTCH INSPECTION DRIVE CLUTCH CONT D 3 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 4 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 MOVEABLE SHEAVE BUSHING INSPECTION 1 Inspect the Teflon coating on the moveable sheave bushing Inspect BOTH sheaves for signs of wear grooving or cracking Clean surfaces with a 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 this chapter 6 18 EBS DRIVEN CLUTCH DISASSEMBLY INSPECTION CAUTION The driven clutch must be disassembled from the helix end to lessen the chance of damage to seals in the one way clutch Review all information be
19. ing Bolt 17 ft lbs 23 Nm PVT Inner Cover Bolts 12 ft los 16 Nm Drive Clutch Spider EBS Clutch 200 ft Ibs O Sa ygdaee sean egeeeeaueuess 271 Nm Drive Clutch Spider Lock Nut Plastic 15 ft lbs 20 3 Drive Clutch Cover Plate 90 in 165 10 Nm 6 4 PVT OPERATION OVERVIEW A All PVT maintenance or repairs should be performed only 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 and 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 inspection of existing components must be the primary objective when troubleshooting and tuning DRIVE CLUTCH OPERATION Driv
20. install drive belt noting direction of rotation Ifa new belt is installed install so numbers can be easily read 14 Only replace PVT outer cover rubber gasket if it is damaged Place the gasket with the narrow side out C Toward outer cover C PVT Cover Gasket 15 Reinstall PVT outer cover and secure with screws 16 Reinstall rear cab assembly panel and seat CGO POLARIS CLUTCH XO The drive clutch spring has two FULL primary functions MNRE aie 1 Controls clutch engagement 280 RPM The springs which have a higher rate when the clutch is in neutral will increase clutch 240 engagement RPM 2 Controls the rate at which the 220 drive belt moves upward in the 200 drive clutch sheaves This is referred to as drive clutch upshift 180 The drive clutch spring is one of the Green most critical components of the PVT 99 Purple system Itis also one of the easiest to 140 service Due to the severe stress the a coil spring is subject to during 120 7041021 Operation it should always be an inspected for tolerance limits during 100 7041022 any clutch diagnosis or repair There are other components which control upshift but the spring is one of 60 the primary components in insuring optimum performance It is very important that the spring is of correct 20 design and is in good condition CAUTION Never shim a drive clutch 25 225 200 1 75 1 50 1
21. ject the side profiles and measure from corner to corner Place a straight edge on each side of the drive belt Place another straight edge on top of belt Measure the distance where the side Straight edges intersect the top as shown in the illustration t Projected Bel W idth CGO POLARIS CLUTCH Belt Width New 1 174 1 188 2 98 3 02 cm Wear Limit 1 125 2 86 cm Inspectbeltfor loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 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 continuously in one spot 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 ora Shorter center distance Remember proper belt deflection is the desired goal not a specific center distance Replace belt if worn past the service limit Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See Troubleshooting Chart atthe end of this chapter for possible causes Distance Clut
22. l 1 Install main puller adapter Item 8 onto puller 2 Install adapter reducer Item 9 3 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 insulated gloves during the removal process 4 Flip sheave over onto puller 5 Install bushing tool Item 2 6 Install lefthand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed CGO POLARIS 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller EBS Driven Clutch Outer Bushing Removal Bushing Tool 2 _ Adapter Reducer 9 Main Adapter 8 10 Remove bushing and removal tool from adapters Discard bushing EBS Driven Backside Outer Bushing Installation 1 Install puller adapter Item 10 onto puller 2 Install adapter Item 9 onto puller EBS Driven Clutch OuterBushing Installation Nut C Bushing Bushing Tool 2 Puller Adapter 10 9 3 Apply Loctite 609 evenly bushing bore inside moveable sheave Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and install assembly into sheave 6 Install left hand thread nut C
23. lightly to expel the moisture This will also 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 Repeat as needed Operate ATV in lowest available range for a short period of time until PVT system Is dry PVT Drain Plug amp O ring CLUTCH 0 PVT OVERHEATING DIANOSIS 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 ATV should be operated in LOW RANGE when pulling or plowing heavy loads or if extended low speed operation is anticipated GENERAL RANGE OPERATION Low Range Heavy pulling basic operational speeds less GUIDELINES than 7 MPH riding through rough terrain swamps mountains etc low ground speeds High Range High ground speeds speeds above 7 MPH Diagnosis of Clutch Drive Belt amp Cover Related Issues 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 ATV after first applying the park brake and perform the turn Driving at low RPM or low ground speed Drive at higher speed or use Low Range The use of Low
24. low before proceeding ONE WAY CLUTCH PRELIMINARY INSPECTION DRIVEN 1 With drive belt removed and transmission in gear hold the inner sheave and rotate the outer sheave of the driven clutch a counterclockwise direction as shown at right The sheave should rotate with only a slight amount of drag There should not be any binding or rough spots Move Freely CGO POLARIS 2 Whenrotated clockwise the outer sheave should lock to the shaft and inner sheave without slipping Lock to Shaft and Outer Sheave 3 Remove driven clutch from the transmission input shaft Do not attempt disassembly of 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 4 Place the driven assembly into the clutch holder Push helix inward Remove snap ring washer helix and spring NOTE The spring is a compression spring only and has no torsional wind CGO POLARIS CLUTCH NOTE Rotating the moveable sheave so that the rollers are not in contact with either helix ramp surfaces will lessen the effort needed to push the helix inward 5 Remove spring seat washer and inspect for wear or damage Replace if worn 6 Inspect surface of rollers for flat spots and wear Rollers must rotate freely on pins without excessive clearance Check the roller pin and roller bore for wear and replac
25. ncorrect for ap Install correct recommended shift weights plication too light Drive clutch binding Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Driven clutch binding Disassemble clean and inspect driven clutch noting worn Sheave bushing and ramp buttons and helix spring location Converter sheaves greasy belt slippage Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive Drive belt worn too narrow Replace belt clutch engage ment Excessive belt sheave clearance with new Perform belt sheave clearance adjustment with shim wash belt ers beneath spider Drive beltturns Wrong belt for application Replace with correct belt over Clutch alignment out of spec Adjust alignment offset Engine mount broken or loose Inspect adjust or replace PVT cover Plugged air intake or outlet Clear obstruction overheating melting Belt slippage due to water oil grease Inspectsystem Clean repair or replace as necessary etc rubbing on cover Seal PVT system ducts Clutches or weight being applied to cover Remove weight Inform operator while in operation Use of High vs low range Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner s Safety and Maintenance Manual Water inge
26. nd bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN b X on spider making sure spacer washers 2870910 to replace rollers and pins Take care installed underneath spider and not to damage roller bushing or bearing surface of positioned properly in recess the new pin during installation X or the marks that were made earlier under weight 4 Rubberbacked buttons can and should be used in all ATV clutches ifthe hollow roller pin is changed to a solid roller pin NOTE The rubber side of the CD POLARIS 6 13 CLUTCH DRIVE CLUTCH REASSEMBLY CONT D 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 or the marks that were made earlier on spider aligns with X or the marks that were made earlier on the 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 Refer to Page 6 3 for torque specification CAUTION Be sure the spider spacer washers are fully seated in the recessed area of the spider Any misalignment will alter clutch balance Inverting the clutch while initially tightening the spider will help position the washers S pacer washers
27. r 9 Main Adapter 8 Piston Pin Puller EBS Drive Clutch Cover Bushing Removal 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 EBS Drive Clutch 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 6 21 CLUTCH EBS DRIVEN BUSHING SERVICE EBS Driven Bushing Removal 1 Install puller adapter Item 10 onto puller 2 InsertEBS main adapter Item onto puller See II 1 3 Install bushing removal tool Item into center of clutch sheave See Ill 2 Bushing Remo
28. stion Cover seals or ducts leaking Find leak and repair as necessary O perator error Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual 6 24 CO POLARIS XWA CLUTCH TROUBLESHOOTING Situation _ Probable Cause Belt slippage 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 Instruct firm effective use of throttle for efficient engage ment PVT noise Belt worn or Separated thin spots loose Replace belt 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 POLARIS 6 25 CLUTCH NOTES 6 26
29. the distance at point A Ifa shim is present it can be removed to decrease the distance at point A Shim Kit PN 2200126 CLUTCH OFFSET Important Inspect clutch alignment and center distance before adjusting offset Offset is correct when rear of tool contacts rear of inner sheave with driven clutch pushed completely inward on shaft and bolt torqued Adjust offset by adding or removing spacer washers between back of driven clutch and spacer Spacer Washer PN 7556401 CGO POLARIS F 1 Install offset alignment tool as shown Remember to measure above and below the shaft centerlines TE Offset Alignment Tool anro should contact rear edge of driven clutch sheave Driven Clutch Offset To adjust add or remove washers from behind the driven clutch ONE WAY CLUTCH INSPECTION DRIVE CLUTCH 1 Rotate one way clutch clockwise as viewed from the cover plate side The clutch should rotate on the shaft with only slight amount of drag Verify there is no 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 CLUTCH DRIVE CLUTCH INSPECTION NOTE Remove cover spring and spider following instructions for drive clutch removal then proceed as follows 1 Remove moveable sheave spacer sleeve and the brass washer Visually inspect the washer for damage Measure t
30. utch Spider Rollers and Roller Pins Drive and Driven Clutch Springs See Pages 6 11 6 12 3 Sheave Faces Clean and inspect for wear PVT System Sealing Refer to appropriate illustrations and photos The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create low pressure area inthe crankcase casting drawing air into the system through an intake duct The opening for this intake ductis located ata high pointon the vehicle location varies by model The intake duct draws fresh air through a vented cover All connecting CGO POLARIS CLUTCH 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 This also will prevent water and other contaminants from entering the PVT area A sealed PVT is especially critical on units subjected to frequent water forging PVT DRYING NOTE If operating the ATV through water be sure to check the PVT cover and other ATV components for water ingestion The ATV should be checked immediately Refer to Owner s Manual for Safe Riding Tips PVT Drain Plug To drain any water that may be trapped inside the PVT cover simply remove the PVT drain plug and O ring located on the bottom of the PVT cover and let the water drain out The PVT drain plug is shown below To further expel water in the PVT cover and to dry out the PVT system shift the transmission to neutral and rev engine s
31. val Tool E 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 evenly around outside of bushing until tiny smoke tailings appear CAUTION Clutch components will be hot In order to avoid serious burns wear insulated gloves during the removal process 7 Turn clutch sheave counterclockwise until bushing is removed and sheave comes free 6 22 8 Remove nut C left hand thread from puller rod and set aside 9 Remove adapters from puller 10 Remove bushing and removal tool from adapters Discard bushing EBS Driven Bushing Installation 1 Slide adapter Item 10 onto puller EBS Driven Clutch Bushing Installation Puller Tool A B Side B toward sheave __ _ r Nut C Bushing Puller Adapter 10 2 Apply Loctite 609 evenly to bushing bore inside moveable sheave 3 Install sheave onto puller belt surface up 4 Place new bushing on side B of installation tool Item A B and slide both over puller rod 5 Install nut C onto puller rod and hand tighten against installation tool 6 Turn clutch sheave counterclockwise until bushing is seated 7 Remove nut C left hand thread from puller rod and set aside 8 Remove installation tool and clutch sheave from puller EBS Driven Backside Outer Bushing Remova
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