1999 Polaris Service Manual
Contents
1. Polaris Industries Inc 5 17 CLUTCHES Drive Clutch 10 98 CLUTCHES Drive Clutch Spider Roller Removal 1 Remove spider buttons using button removal tool Remove shims if any are installed and note location Spider Button Removal Tool PN 2870985 2 Place spider on a vise or in an arbor press Using a pin punch drive out the roller pin Roller Installation 1 Start a replacement roller on each leg driving a pin in 100 125 25 32 cm beyond the first land of the spider leg A Remove any aluminum burrs from pin protruding from spider 2 Install one washer onto pin 10 98 5 18 Polaris Industries Inc CLUTCHES Drive Clutch Roller Installation Cont 3 Place roller on pin as it protrudes from first land 4 Place a second washer on other side of roller 5 Install service tool as shown 6 Place spider on a vise anvil and drive roller pin through to second land of spider Use care to start the pin straight Aluminum burrs could pass through into the roller bushing causing it to bind and stick Also use care to make sure the roller remains aligned when the pin is driven through The roller bushing could be damaged causing premature wear and roller fail ure Spider Button Shimming 1 Determine how many shims are to be used NOTE Ashim kit is available which contains an assort ment of shims including 002 005 and 010 Shim Kit PN 22003872. 10 98 5 32 Polaris Industries Inc Drive Belt Inspection 1 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 e The top edges have been trimmed on some drive belts It will be necessary to project the side profiles and measure from corner to corner e Place a straight edge on each side of the drive belt e Place another straight edge on top of belt e Measure the distance where the side straight edges intersect the top as shown in the illustra tion at right 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Replace if necessary 3 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 Belt Wear Burn Diagnosis CLUTCHES Drive Belt t Projected Bel rea Width E v 7 Belt Wear Burn Diagnosis Possible Cause Of Wear Or Burning Solution Driving at or about engagement RPM for extended periods in all types of conditions Cold weather startups Towing another machine at or about engagement RPM Spinning track while vehicle is stuck high RPM low vehicle speed high ambient temp Example 8000 RPM 10mph vehicle speed 60 mph indicated on speedometer Ice and snow piled up between track and tunnel
3. Polaris Industries Inc 5 19 10 98 CLUTCHES Drive Clutch Spider Button Shimming Cont 2 Measure the dimension between towers at the lower half of the towers as shown 3 Install spider buttons using a soft face hammer 4 Record width of spider buttons on each leg 5 Add shims beneath trailing side spider button to obtain specified button to tower clearance when assembled Button to Tower Clearance P 85 P 90 002 05 mm 10 98 5 20 Polaris Industries Inc Drive Clutch Assembly 1 Place the correct number of spacer washers beneath the spider 2 Assemble clutch making sure X marks on movable sheave and spider or reference marks made before disassembly are aligned to achieve proper balance NOTE If belt to sheave clearance is being changed by adding or removing washers from under the spider and the sheaves were marked before disassembly follow in dexing procedure on page 5 24 3 Torque spider to specification Spider Torque P85 and P90 200 ft Ibs 27 6 kgm Spider Removal Tool PN 2870341 4 Torque jam nut to specification P 85 Clutches Install weights with weight pin nut on trailing side Use new nuts to ensure proper retention Torque nut to 30 in Ibs Jam Nut Torque P85 models only 235 ft Ibs 32
4. Remove nut from puller rod and set aside Install main adapter Item 8 onto puller See Ill 1 Working from inside of moveable sheave insert removal tool Item 1 into center of sheave With towers pointing away from vise slide sheave onto puller rod Install nut removed in step 2 onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Turn sheave counterclockwise on puller rod until it comes free Remove nut from puller rod and set aside Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Remove retaining ring from inside adapter and set aside Polaris Industries Inc 5 41 Piston Pin Ul 4 Main Adaptor 10 98 CLUTCHES Clutch Bushing Replacement P 85 P 85 Drive Clutch Movable Sheave Bushing Installation 1 Place main adapter Item 8 on puller 2 Push new bushing into center of sheave by hand 3 Insert installation tool Item 1 into center of sheave and with towers pointing toward vise slide sheave onto puller rod 4 Install nut on puller rod and hand tighten Turn barrel to apply additional tension if needed Turn sheave counterclockwise until bushing is seated Remove nut from puller rod and set aside Remove sheave from puller Remove installation tool o on on Insert retaining ring removed in step 9 and installation tool into center of sheave 10 With towers pointing toward vise install sheav
5. f Install correct parts and or adjust to match engine application and ma chine use 10 98 5 54 Polaris Industries Inc CLUTCHES Belt Wear Burn Diagnosis Belt Wear Burn Diagnosis Possible Cause Of Wear Or Burning Driving at or about engagement RPM for extended periods in all types of conditions Cold weather startups Towing another machine at or about engagement RPM Spinning track while vehicle is stuck high RPM low vehicle speed high ambient temp Example 8000 RPM 10mph vehicle speed 60 mph indicated on speedometer Ice and snow piled up between track and tunnel overnight or after stopping for a long period of time enough to re freeze the snow Poor running engine Bog Miss Backfire etc Loading machine on trailer Drive at higher RPM if possible Gear the machine down Make sure belt deflection is at 1 25 to achieve optimum starting ratio Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient driveaway in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for short durations for initial cold driveaway When possible do not go in deep snow when towing another machine Use fast effective throttle to en gage the clutch Not all machines are intended for pulling heavy loads or other machines Lower the ge
6. 5 Measure the total thickness of the spacer washers installed beneath spider and record NOTE In order to maintain proper belt to sheave clear ance and clutch balance the same washers or equiva lent total thickness must be reinstalled during assembly If sheaves are not marked or if total thickness of existing shim washers under spider is not recorded clutch will be out of balance when reassembled and must be replaced Be sure to follow indexing procedure on page 5 24 if belt to sheave clearance is being adjusted 6 Inspect both sheave surfaces for wear or damage Inspect movable sheave bushing See page 5 41 for inspection and repair procedure 7 Using an 1 8 Allen wrench with a 3 8 combination wrench remove drive clutch fly weights Note direction of weight pin with nut on trailing side Inspect each weight Surface should be smooth with no waves or galling Place bolt inside weight to check flyweight bushing and pin surface for wear NOTE The weight bushing is not a service part and both weight and pin must be replaced if worn 8 Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Roller can also be inspected by rolling with finger to feel for flat spots roughness or loose bushing Also inspect to see if roller and bushing are separating Bushing must fit tightly in roller Replace roller and pin if roller fails to roll smoothly flat spots or if bushing is loose
7. Note size and number of shim washers between sheaves 7 Note condition of moveable sheave bushing Install helix into bushing It should slide freely without binding See page 5 43 for bushing replacement 8 Polish helix with a fine emery cloth to remove any sharp edges or build up which may cause sticking se Se i aaaaaaaaaaaasasaaaaaaaaaaaaaaaaaaaaaaIaamamaaaaaaasasaassasasasesasasasasla Polaris Industries Inc 5 27 10 98 CLUTCHES Driven Clutch Assembly 1 Install appropriate washer s on fixed shaft Optional Thin Adjustment Washer P 85 048 PN 7555899 2 Slide moveable sheave on fixed shaft 3 Install driven clutch spring Be sure spring tab is seated in hole in moveable sheave Refer to specifications in front of this section for driven spring setting e P 85 driven clutches have 1 spring locat ing hole in the movable sheave and 4 holes in the helix P 90 driven clutches have 2 spring locat ing holes in the movable sheave and 3 in the helix NOTE The driven clutch helix moveable assembly has several different spring locations which affect clutch shift ing and RPMs Tighter spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when pulling or negotiating a hill The lighter tension posi tions will tend to have a slower downshift and a harder up shift P 90 Moveable Spring Example Helix Sheave Tension B 1 Heavy Spring B 2 Position A 1
8. 43 kgm Jam Nut Tool PN 2870338 Weight Pin Nut Torque 30 In Lbs 34 kgm Polaris Industries Inc 5 21 CLUTCHES Drive Clutch 10 98 CLUTCHES Drive Clutch Assembly Cont 5 Install spring and cover Torque cover bolts evenly to specification CAUTION Carefully align bushing with shaft during installation of cover to prevent bushing damage Maintain alignment by tightening cover bolts evenly and carefully Spider Cover Bolt Torque 90 in Ibs 1 03 kgm Installation 1 Slight galling or scoring of the bore taper can usually be corrected using a tapered reamer Place reamer in a vise and lubricate with cutting oil Clean taper by manually rotating clutch clockwise Tapered Reamer PN 2870576 2 Check crankshaft taper for galling or scoring If necessary clean taper evenly with 200 grit emery cloth 3 Both clutch taper and crankshaft taper should be clean and dry NOTE Do not use harsh cleaners which may cause clutch taper to corrode during use This will cause diffi culty when removing clutch in future Clean clutch taper with lacquer thinner or isopropyl alcohol 10 98 5 22 Polaris Industries Inc Installation Cont 4 Slide clutch fully onto crankshaft taper 5 Install retaining bolt with any spacers washers or O rings See appropriate parts manual for type and placement of
9. Belt Deflection 0 eee eee 5 34 5 35 Clutch Offset Alignment 2 eee eee 5 36 5 37 Torque Stop Adjustment 00 08 5 37 Belt to Sheave Clearance 00 eee 5 38 Clutch Bushing Replacement P 85 5 39 5 44 Clutch Bushing Replacement P 90 5 45 5 52 Troubleshooting seed ceed Si Renee te access 5 53 5 55 CLUTCHES Service Tools A WARNING All drive clutch maintenance disassembly and assembly must be performed only by an authorized Polaris dealer who has attended current model Dealer Service Seminars has received a certificate of completion and displays the Polaris Servicing Dealer decal Because of the critical nature and precision balance incorporated into the drive clutch it is absolutely essential that no attempt at clutch disassembly and or repair be made without factory authorized tools and service procedures Essential Drive Clutch Tools Refer to the Service Too Catalog PN 9914681 for photos and descriptions of all tools A tool catalog update is available through the Polaris parts department The part number is 9915235 Description Part Number Offset Alignment Tool 21 32 1 7 cm P 90 Clutches 2870914 Offset Alignment Tool 5 8 1 6 cm P 85 Clutches 2870426 T Handle Drive Clutch Puller Large Shaft ID 2870506 Drive Clutch Puller 14mm Small Shaft ID 2871855 Drive Clutch Pul
10. clutch part number Polaris Industries Inc 5 15 CLUTCHES Drive Clutch Date Code Last 3 digits of part number 10 98 CLUTCHES Drive Clutch Disassembly and Inspection 1 Install drive clutch in clutch compression tool 8700220 Mark both moveable and fixed sheave cover and spider with a permanent marker Sheaves must be marked to provide a reference point for clutch balance and spider indexing If the sheaves are not marked and spider shim washers are changed or misplaced the will clutch will be out of balance and must be replaced See page 5 24 for indexing procedure 2 Carefully and evenly remove cover attaching bolts Do not allow side loading or misalignment of cover or bushing may be damaged Remember there is spring tension on the cover Inspect cover bushing for wear See page 5 39 for inspection and repair procedure Drive Clutch Compression Tool PN 8700220 rive Clutch Holding Fixture PN 2871358 3 Mount drive clutch securely in the holding fixture On models equipped with a spider jam nut P 85 Clutches remove jam nut in a counterclockwise direction standard thread using the special tool Spider Spanner Jam Nut Tool PN 2870338 4 Install spider removal tool and remove spider in a counterclockwise direction standard thread Spider Removal Tool PN 2870341 10 98 5 16 Polaris Industries Inc Disassembly Cont
11. its ratio It can be readjusted by relocat ing the spring in the helix which in turn increases or decreases the amount of load required to change the ratio Driven Clutch Typical P 85 10 98 5 14 Polaris Industries Inc Removal 1 Hold clutch with strap wrench Remove drive clutch retaining bolt grease puller thread and tip lightly and install puller into clutch Tighten puller with a wrench or strike t bar with a hammer until clutch is removed 7 see Wrench PN fea Cl eye S Clutch Puller PN 2872085 700 800 XCR a NOTE 440 500 600 amp 700 domestic twins use puller PN 2871855 The 1999 Trail RMK and Supersport use puller PN 2872084 and the 700 800 XCR use puller PN 2872085 2 Slight galling or scoring of bore taper can usually be corrected using a tapered reamer Place reamer in a vise and lubricate with cutting oil Clean clutch taper by manually rotating clutch clockwise Do not ream taper more than required to remove galling or scoring Never use power tools to ream taper of drive clutch ban A Never use an air impact wrench for installing or removing a drive clutch It will loosen the spider torque value and could cause engine crankshaft damage Identification This number indicates internal clutch component varia tion for individual engines For easy identification refer to the three numbers behind date code on clutch cover plate These numbers are the last three digits of the
12. may not be evident if other drive or driven clutch components are substandard NOTE All R Series Mod M T1 and 40 36 helix ramps are cut 0 060 deeper in the snap ring pocket These are made so the driven clutch can open far enough for ful shift out with wide 1 7 16 belts standard on Storm and 600 700 twins If these helix ramps are used with narrow belts 2 two additional for a total of three 030 8 mm washers PN 7556804 should be installed under the snap ring to prevent the belt from touching the inner hub at full shift which can cause belt failure Wide belt models Storm and 600 amp 700 twins use only the existing washer under the snap ring 6 Force helix down into place exposing snap ring groove Polaris Industries Inc 5 29 10 98 CLUTCHES Driven Clutch Assembly Cont 7 Install retainer where applicable on P 90 spacer washer s and snap ring Snap ring should be installed with flat machined side up or toward jackshaft bearing NOTE On models equipped with snap ring retainers as shown below retainer may stay on back of snap ring when clutch is removed Pry lightly to remove retainer and gain access to snap ring Refer to illustration below ol Snap To l NOTE Always install snap ring with Ring Retainer chamfer towards helix sharp edge out a ward 8 Allow sheaves to close Test clutch by pre loading movable sheave 1 4 turn co
13. overnight or after stopping for a long period of time enough to re freeze the snow Poor running engine Bog Miss Backfire etc Loading machine on trailer Clutch malfunction Slow easy belt engagement easing on the throttle Polaris Industries Inc 5 33 Drive at higher RPM if possible Gear the machine down Make sure belt deflection is at 1 25 to achieve optimum starting ratio Be patient Warm up engine at least 5 minutes or until it readily responds to throttle input For the quickest most efficient driveaway in extreme cold weather take drive belt off machine and bring it in to a warm environment Break skis and track loose from the snow Engage throttle aggressively for short durations for initial cold drive away When possible do not go in deep snow when towing another ma chine Use fast effective throttle to engage the clutch Not all ma chines are intended for pulling heavy loads or other machines Lower the gear ratio Remove windage plates from driven clutch If possible move to better snow conditions and reduce RPM Avoid riding in very high ambient temperatures Break loose snow and ice under tunnel Allow longer than normal warmup Allow belt to warm sufficiently and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Maintain good state of tune including throttle and choke synchro nization Check for fouled spark plug s Check for foreign material in c
14. vise slide sheave onto puller rod 12 Install nut on puller rod and hand tighten Turn barre to apply additional tension if needed 13 Turn sheave and barrel together counterclockwise until bushing is seated 14 Remove nut from puller rod and set aside 15 Remove sheave from puller 16 Remove installation tool 10 98 5 46 Polaris Industries Inc CLUTCHES Clutch Bushing P 90 P 90 Drive Clutch Cover Bushing Removal 1 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 Turn 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 Industries Inc 5 47 10 98 CLUTCHES Clutch Bushing P 90 P 90 Drive Clutch Cover Bushing Installation 8 On Garmax style bushings PN 3576516 apply Loctite 680 retaining compound PN 2870584 to the outer surface of the bushing Retaining compound is not required on bronze Teflon type bushings PN 3576510 Do not lubricate bushings or premature wear will result Working from inside of cover insert bushing and bushing installation to
15. B 3 A 2 A 3 Soft P 90 production settings are usually B2 P 85 production settings are usually 2 4 Align inner keyway P 85 or boss spline P 90 between the helix and movable sheave With the spring in place slide helix onto shaft 5 12mm 10 98 5 28 Polaris Industries Inc CLUTCHES Driven Clutch Assembly Cont Helix Angles and Effects The driven clutch helix was selected for overall performance in relation to the other driven system components In fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift we recommend trying a helix change before changing other components Polaris has several helix angles available for the P 85 and P 90 driven clutch Refer to the chart below for specific angle effects and identification Helix Ramps CUGE E GEAL s ora Pas 40 36 me ssa ea Pe me ero sos Pe me presos Pe me mez 50 36 es a 365 Po 40 38 36 sner 0303 P ess rnez sss P0 38 36 34 _ s1gT163 383034 P0 E GE E Po 5 Hold fixed sheave and turn movable sheave 1 4 turn counterclockwise The helix spring should always be adjusted within its limits before a helix change is performed The normal rate of change between helix angle steps is 250 RPM under full throttle This is approximately the same result as in going from the No 1 to No 4 spring position P 85 NOTE Increasing spring tension increases engine RPM RPM changes
16. CHAPTER 5 CLUTCHES Clutch Service Tools 0 0c c eee eee e eens 5 1 Drive Clutch Weight Identification 5 2 5 4 Drive Clutch Spring Rates nosaus 5 5 Drive Clutch Spring Data 00005 5 6 Driven Clutch Spring Data Rates 5 7 P 85 Drive Clutch Exploded View 5 8 P 85 Driven Clutch Exploded View 5 9 P 90 Drive Clutch Exploded View 5 10 P 90 Driven Clutch Exploded View 5 11 Drive Clutch Operation 0 0 02 eee eee 5 12 5 13 Driven Clutch Operation 0 0002 eee 5 14 Drive Clutch Identification andRemoval 5 15 Drive Clutch Disassembly and Inspection 5 16 5 17 Spider Roller Removal 2 2005 5 18 Roller Installation 0 2 20 ee eee eee eee 5 18 5 19 Spider Assembly 2202 tuwarnatsyeon ese reiaas 5 19 5 20 Drive Clutch Assembly 0000 5 21 5 22 Drive Clutch Installation 00000 5 22 5 23 Spider Indexing wi442 caskae s oscil sheseda aes 5 24 Driven Clutch Removal 0 050 508 cree ot 5 25 Driven Clutch Disassembly 4 5 26 5 27 Driven Clutch Assembly 02 05 5 28 5 30 Helix Angles and Effects 0 05 5 29 Driven Clutch Installation 2025 5 31 Drive Belt Information 000 c ee eee 5 32 Drive Belt Inspection Troubleshooting 5 33 Drive
17. Some models with P 90 clutches use a snap ring retainer cup to captivate the snap ring On these models end float should be adjusted between 000 and 010 000 254 mm Torque bolt to specification Driven Clutch Torque Float P 85 P 90 040 080 1 2 mm P 90 with retainer 000 010 000 254 mm Polaris Industries Inc 5 31 CLUTCHES Driven Clutch 10 98 CLUTCHES Drive Belt Drive Belt Part No Belt Width Projected Side Angle Overall Circum ference Center pa 3211042 1 375 72 y 47 250 Common production belt for P 85 systems 34 93mm 3211045 1 375 12 00 47 125 Close tolerance version of 3211042 34 93mm 3211058 1 250 11 00 43 313 Indy Lite belt P 90 31 75mm 3211059 1 250 12 00 45 125 Longer Indy Sport Belt P 90 31 75mm 3211061 1 375 12 00 47 188 CVT version of 3211045 34 93mm 3211065 1 438 12 50 48 375 CVT Double Cog Storm belt 36 53mm 3211066 1 375 28 12 00 47 250 Double cog CVT thicker than 3211070 Pro 34 93mm duction on higher horsepower snowmobiles 3211067 1 375 12 00 47 250 Double cog Good for short runs on higher 34 93mm horsepower engines Drag Racers Good for lower horsepower trail riding 3211070 1 375 12 eee 47 250 Common production bel
18. ar ratio Remove windage plates from driven clutch If possible move to better snow condi tions and reduce RPM Avoid riding in very high am bient temperatures Break loose snow and ice under tunnel Allow longer than normal warmup Allow belt to warm sufficiently and increase grip ability on clutch sheaves Use fast effective throttle when engaging clutch Maintain good state of tune including throttle and choke synchronization Check for fouled spark plug s Check for foreign material in carbs Make sure no water or ice in fuel tank lines or carbure tors Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning freely Use enough speed to drive com pletely onto trailer If machine cannot be driven com pletely onto trailer it may need to be pulled or pushed to avoid belt wear burning Clutch malfunction Check for correct clutch components Slow easy belt engagement easing on the throttle Use fast effective throttle to engage the clutch Polaris Industries Inc 5 55 10 98
19. arbs Make sure no water or ice in fuel tank lines or carbure tors Use caution when loading machine Carbide skags may gouge into trailer and prevent drive train from spinning freely Use enough speed to drive completely onto trailer If machine cannot be driven completely onto trailer it may need to be pulled or pushed to avoid belt wear burning Check for correct clutch components Use fast effective throttle to engage the clutch 10 98 CLUTCHES Drive Belt Belt Deflection Too much belt deflection If the belt is too long or the center distance too short the initial starting ratio will be Belt too high on initial engagement too high resulting in performance loss This is due to the belt rising too high in the drive clutch sheaves upon en gagement Not enough belt deflection belt too tight If the drive belt is too short or the center distance too long the ratio will again be incorrect In addition the machine may creep when the engine idles causing damage to the in ternal face of the drive belt 10 98 5 34 Polaris Industries Inc CLUTCHES Drive Belt Measuring Belt Deflection IMPORTANT NOTE Do not apply excessive pressure to force belt into driven sheaves This will result in an improper measurement If belt deflection cannot be adjusted within specification using methods below inspect center distance and compare to specifications beginning on page 6 3 1 Measure belt deflection with both c
20. chieve proper offset 4 Most models require the driven clutch to float on the jackshaft After adjusting offset add or remove shim washers from the retaining bolt to provide a 030 060 75 1 5mm of float on jackshaft This will prevent side loads on the jackshaft bearing NOTE On models with driven clutch snap ring retainer Se Transport Lite Touring Sport Touring etc the clutch ge is mounted firmly on the shaft without float P90 Electric Start 1 28 P85 Electric Start 1 00 NOTE When checking electric start models use a straight edge as shown in Ill 2 If alignment is off loosen the engine mounts and shift engine as required to obtain the proper offset and alignment Driven Clutch Bolt Torque 12 ft Ibs 1 66 kgm 10 98 5 36 Polaris Industries Inc CLUTCHES Drive Belt Clutch Alignment Inspection NOTE Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it s mounts Under toad the engine will pull back slightly so both clutches are in alignment 1 After clutch offset has been verified inspect alignment 2 Install proper alignment tool depending on type of clutch as shown in lll 1 page 5 36 3 There should be a 060 090 1 5 2 25 mm gap between front of driven clutch and tool with the tool just touching at the rear Up to 125 3 1 mm gap is acceptable in the front on new machines Clu
21. ded with replacement P 90 clutches and must be purchased separately 10 98 5 10 Polaris Industries Inc CLUTCHES P 90 Driven Clutch Exploded View Do not lubricate driven clutch components except inside of ramp helix hub to reduce fretting and corrosion Bolt Retaining Ring Ramp Button ia S Moveable Bushing 1 Moveable Bushing 1 2 Stationary Sheave Moveable Sheave F C a Washer P A Washer Driven Clutch Asm A Snap Ring Retainer Used on some models Can be retro fit to all P 90 models used in heavy load conditions Install Extreme Duty P 90 Mounting Kit PN 2200752 Replacement driven clutches come complete with ramp and spring The moveable and station ary sheaves cannot be ordered as separate service parts Polaris Industries Inc 5 11 10 98 CLUTCHES Operation The Polaris drive system is a centrifugally actuated variable speed belt drive unit The drive clutch driven clutch and belt make up the torque converter system Each clutch comes from the factory with the proper internal components installed for its specific engine model Therefore modifications or variations of components at random are never recommended Proper converter setup and adjustments of existing components must be the primary objective in converter operation diagnosis All converter maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsor
22. e onto puller rod 11 Instali nut on puller rod and hand tighten Turn barrel to apply additional tension if needed 12 Turn sheave counterclockwise until ring is seated 13 Remove nut from puller rod and set aside 14 Remove sheave from puller 15 Remove installation tool Do not lubricate bushings or premature wear will result 10 98 5 42 Polaris Industries Inc CLUTCHES Clutch Bushings P 85 P 85 Driven Clutch Movable Sheave Large Bushing Removal NOTE The P 85 driven moveable has a split bushing Note the position of this split during bushing removal See Ill 2 Note posi Moveable Sheave Bushing Inspect tion Replace the cover bushing if moe brass than Teflon i is visible on the o bashing a ee 1 Inspect bushing and replace if excessively worn 2 Insert bushing removal tool Item 6 into sheave Bushing centering split on tool NOTE The split must be removal tool touching the tool See lll 2 3 Install main adapter as illustrated Install bridge Item 7 onto puller with legs pointing toward clutch See Ill 3 4 From the outside insert thumb through center of sheave Using downward pressure hold bushing removal tool tightly in place 5 With back side toward vise slide sheave onto puller 6 Install nut onto puller rod and hand tighten Slowly align clutch with bridge and turn puller barrel to increase tension if needed 7 Turn sheave counterclockwise until bushing is re
23. ear at the top of the clutch 10 98 5 12 Polaris Industries Inc CLUTCHES Operation 9000 8000 ame ENGINE OPERATING RANGE 250 RPM eo 5000 gt es ENGAGEMENT 7000 RPM 3000 If the weights are too heavy or spring rate too low the engine RPM will be low and the drive clutch will upshift too fast keeping the engine out of its power band ENGAGEMENT 4000 If the weights and spring are matched properly the engine RPM will go to the desired range and remain there on both upshift and backshift Polaris Industries Inc 5 13 10 98 CLUTCHES Driven Clutch Operation The driven clutch operates in conjunction with the drive clutch Its function is to maintain drive belt tension pre venting slippage and sense variations in load requirements necessary to maintain optimum engine torque output and load requirements from the track Output torque is transmitted through the chaincase jackshaft and chain case to the front drive shaft and track When the load on the driven clutch is increased and becomes greater than the torque delivered from the engine the driven clutch becomes dominant and overrides the drive clutch The driven clutch downshifts into a ratio which will match the increased load Because the driven clutch can sense and shift into the proper ratio engine RPM will remain within the specified range Driven Clutch Adjustments The driven clutch has a provision for varying the torque required to change
24. earance with a new belt 2 Install feeler gage between other sheave and belt Belt to Sheave Clearance 020 015 5 mm 4mm Belt to Sheave Clearance Adjustment Belt to sheave clearance can be adjusted in two ways 1 Try several new belts to achieve proper clearance 2 Can add or remove shims from under the spider to increase or decrease belt to sheave clearance See Spider indexing on page 5 24 NOTE Spider indexing affects clutch balance and belt to sheave clearance Read procedures carefully before proceeding NOTE Belts with various widths will also affect belt deflection since they will fit differently in the driven clutch Deflection should be checked per procedure on page 5 35 10 98 5 38 Polaris Industries Inc Kit PN 2871025 Ite 1 O o 8 9 10 11 You will need to supply P 85 Drive Clutch Cover Bushing Removal 1 Disassemble clutch as outlined in this section Inspect or measure bushing and replace if worn beyon service limit Note Bushing must be installed in cove There are two types of bushings used Refer to thi following specifications Qty Part Description 1 P 85 Drive Clutch Moveable Bushing Removal and Installation Too 1 P 90 Drive Clutch and Driven Clutch Bushing Installation Tool 1 Drive Clutch Cover Bushing Removal and Installation Tool for all drive clutches 1 P 85 Driven Clutch DU Split Bushing Installation Tool 1 P 90 Driven Clutch Bushing Rem
25. ed service training seminar and understands the proper procedures as outlined in this manual Because of the critical nature and precision balance incorporated into the drive clutch it is absolutely essential that no attempt at clutch disassembly and or repair be made without factory authorized special tools and service procedures Any unauthorized modifications to clutches such as adding or removing weights will void the warranty Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground This is accomplished by weights and a spring inside the unit which react to the centrifugal force from the engine RPM The spring and weights work in combination In a properly set up clutch the maximum desired operating RPM will be reached immediately after clutch engagement under full throttle conditions To gain optimum power this RPM should be maintained As centrifugal force pushes the weights against the rollers the moveable sheave will force the belt to climb up the drive clutch sheave and increase vehicle speed 8000 __ ENGINEJOPERATING RANGE 250 RPNL__ oe y 6000 Cc 4 5000 ee ec ENGAGEMENT zzo 3000 If the weights are too light or the spring rate too high the maximum RPM will be too great and the drive belt will not move into high g
26. embly no longer align There are two ways to bring the sheave marks into alignment e Vary the amount and thickness of spacer washers Washer thickness may vary slightly e Re index marked spider leg to another tower This can be done because spider has little effect on overall clutch balance Re indexing the spider 1 3 turn clockwise or 1 leg will allow the realignment of the moveable and stationary sheaves as previously marked For example e 020 or 032 washer removed re index spider clockwise 1 3 turn e 050 or 064 washer removed re index spider clockwise 1 3 turn e Two 050 or 064 washers removed re index clockwise 2 3 turn NOTE Alignment marks should be within 1 25 mm af ter final assembly and torquing 10 98 5 24 Polaris Industries Inc CLUTCHES Driven Clutch Driven Clutch Removal 1 Remove driven clutch retaining bolt 2 Slide driven clutch off jackshaft It may be necessary to use a puller on some driven clutches P 85 clutches externally adjustable can be removed using a 3 point flywheel or steering whee puller and the 1 4 20 adjustment bolt holes Usea suitable spacer on the end of the jackshaft P 90 Driven Clutch Puller gt PN 2871056 3 Inspect jackshaft keyway splines P 90s for wear or damage NOTE Notice the number and thickness of shim washers between driven clutch and jackshaft bearing These must be replaced
27. eplace Excessive belt deflection Subtract driven clutch wash ers Improper offset alignment Inspect adjust Broken or misadjusted torque stop Inspect adjust replace Broken motor mount Inspect replace Jackshaft bearing seizure Replace Polaris Industries Inc 5 53 10 98 CLUTCHES Clutch System Troubleshooting SYMPTOMS PROBABLE CAUSE Engine RPM below specified a Wrong or broken drive clutch spring operating range although en b Drive clutch shift weight too heavy gine is properly tuned c Driven clutch spring broken or installed in wrong helix location d Drive belt too long e Improper driven clutch setup REMEDY j a Replace with recommended spring b Install correct shift weight kit to match engine application c Replace spring refer to proper installation location d Install new belt and or adjust belt tension e Install correct parts and or adjust to match engine application and ma chine use Erratic engine operating RPM during acceleration or load variations Disassemble drive clutch inspect shift weights for wear and free operation Clean clutches install new belt Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace ramp buttons Inspect moveable sheave for excessive bushing clearance replace Drive clutch binding or driven clutch malfuncti
28. factors Included in these are converter offset and alignment belt tension belt to sheave clearance and internal condition of the drive and driv en clutch components One of the most critical and easily serviced parts is the drive clutch spring Due to the severe stress the spring is subject to during operation it should always be inspected and checked for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure free length from outer coil surfaces as shown Refer to the chart above for specific free length measurements and tolerances In addition to proper free length the spring coils should be parallel to one another when placed on a flat sur face Distortion of the spring indicates stress fatigue Replacement is required 10 98 5 6 Polaris Industries Inc Driven Clutch Spring Data ne Red 7041296 Blue 7041646 Silver Blue 140 120 100 Torque inch Ibs Load in Pounds ee A PS jo oO k 2 5 Polaris Industries Inc CLUTCHES Driven Clutch Spring Rates Driven Spring Charts Blue Silver or Silver Blue Gold and Black Red _ Silver Blue Gold and Black Red Compression Distance in 1 375 5 7 10 98 CLUTCHES P 85 Drive Clutch Exploded View Typical Do not lubricate drive clutch components Washer Roller Jam e Weig
29. ht 41 51 Gram Weight 47 5 1 PN 5630063 PN 5630080 EEG Gram Weight 4941 Gram Weight 51 Gram Weight 53 1 Gram Weight 32 5 1 PN 5630225 PN 5610088 PN 5630174 PN 5630227 agg M1 Modified Gram Wear 57 5 1 Gram Weight 46 041 Gram ane 39 1 Gram TR 42 1 PN 5630229 PN 5630301 PN 5630144 PN 5630089 10 98 5 2 Polaris Industries Inc CLUTCHES Drive Clutch Weight Identification Actual Size rec Gram Weight 4441 Gram We 53 541 Gram eM 50 1 Gram ae 52 1 PN 5630065 PN 5630234 PN 5630243 PN 5630244 10 Bushed 10M W Bushed Gram Weight 47 541 Gram Wee 55 541 Gram Weight 51 51 Gram Weight 4641 PN 5630245 PN 5630274 PN 1321526 PN 1321527 10M Bushed 10M Blue Bushed 10M Red Bushed Gram Weight 49 5 1 Gram Weight 47 5 1 Gram Weight 44 1 PN 1321528 PN 1321529 PN 1321530 Polaris Industries Inc 5 3 10 98 CLUTCHES Drive Clutch Weight Identification Actual Size 10 AL Bushed 10 66 Bushed 10 64 Bushed 10 62 Bushed Gram Weight 53 1 Gram Weight 66 Gram Weight 64 Gram Weight 62 PN 1321531 PN 1321584 PN 1321585 PN 1321586 10 60 Bushed 10 58 Bushed 10A Bushed 10 56 Bushed Glam Welght 60 Gram Weight 58 Gram Weight 55 Gram Weight 56 1 PN 1321587 PN 1321588 PN 1321589 PN 1321684 10 54 Bushed S53B S53R l S55R Gram Weight 54 1 Gram Weight 49 1 Gram Weight 51 1 Gram Weight 53 1 PN 1321685 PN 1321730 PN 1321731 PN 1321759 10 98 5 4 Polaris Industries Inc FORCE POUNDS CLUTCHES Drive Clutch Spring Rates The f
30. ht w Bushing i BA o Weight Pin Clutch Assembly Less weights spring Fixed Sheave Replacement clutches come complete and balanced without clutch weights and clutch spring The clutch cover spider and sheaves cannot be purchased separately as replacement parts 10 98 5 8 Polaris Industries Inc CLUTCHES P 85 Driven Clutch Exploded View Typical Do not lubricate driven clutch components except inside of ramp helix hub to reduce fretting and corrosion Stationary Sheave Driven Cap Driven Plate Driven Bushing Adjustment Cam k AE i IDR EEN ex a al f A A 7 ae Gr GO Ol GPE GO Pa i Wa i Button ee Clutch Assembly Replacement driven clutches come complete with ramp and spring The moveable and station ary sheaves cannot be ordered as separate service parts Polaris Industries Inc 5 9 10 98 CLUTCHES P 90 Drive Clutch Exploded View Typical Do not lubricate drive clutch components Washer Roller Weight w Bushing Weight Pin VAY VO i A ou Ring Gear Va Where Applicable Roller Pin SZ lt Guide Button Spider Spacer Moveable Bushing Moveable Sheave Fixed Sheave Clutch Assembly Less weights spring Replacement clutches come complete and balanced without clutch weights and clutch spring The clutch cover spider and sheaves cannot be purchased separately as replacement parts Ring gears are not inclu
31. ler 99 550 Fuji Engines 2872084 Drive Clutch Puller 99 700 800 XCR 205 2872085 Strap Wrench eeror cee dad AEEA dew ta AE AAO AR 2870336 Replacement Strap for 2870336 0 eee cece eee 2870389 Spider Spanner Nut Driver Jam Nut 00085 2870338 Spider Removal Installation Tool 0 eee eee ee 2870341 Molding FIXtUIC ss secs niece eee a Rah Sin eed ie die sade eat ke 2871358 Holding Fixture Tab 0 0 cc cece eee ccc eee eens 5130518 Tapered Reamer ccc cece cece eee e teen eee rnrn 2870576 Spider Button Tool i eerren ee cee eee cee ence eee eens 2870985 Clutch Bushing Rebuild Tool Kit P 85 P90 2871025 P 85 Drive Clutch Compression Tool 0 ee sees 2870984 Driven Clutch Puller P 90 22 0 2 ccc eee cece cee eee eee 2871056 Torque Wrench 250 ft Ib 2 cece cee eee eee Commercially Available Torque Wrench 0 200 in Ib 2 eee ee Commercially Available Clutch Compression Tool 0 c cee nee cece cease 8700220 Clutch Holding Wrench 0 cece eee nee eee ees 9314177 SEP ButtOn TOOL scone eck ceca seh ade wet AAE OE Re as 8716010 Heea Oe Watered net ase tek taltaeatade as 8716020 Polaris Industries Inc 5 1 10 98 CLUTCHES Drive Clutch Weight Identification Actual Size falls U sf Gram Weight 34 1 Gram Weight 37 5 1 G B Modified A PN 5630107 PN 5630109 Gram Weig
32. ll nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed 8 Turn clutch cover counterclockwise on puller rod until bushing is removed 9 Remove nut from puller rod and set aside 10 Remove bushing and bushing removal tool from puller Discard bushing P 85 Drive Clutch Cover Bushing Installation 1 On Garmax style bushings PN 3576516 apply Loctite 680 retaining compound PN 2870584 to the outer surface of the bushing Retaining compound is not required on bronze Teflon type bushings PN 3576510 Do not lubricate bushings or premature wear will result 2 Working from inside of cover insert 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 and take installation tool and clutch cover off rod 7 Squeezing ends of snap ring gently fit ring into clutch cover 10 98 5 40 Polaris Industries Inc CLUTCHES Clutch Bushing Replacement P 85 P 85 Drive Clutch Movable Sheave Bushing Removal 10 Inspect bushing and replace if excessively worn Install handle end of piston pin puller PN 2870386 securely into bench vise and lightly grease puller threads
33. lutches at rest and in their full neutral position Straight Edge 2 Place a straight edge on the belt and apply downward 1 1 4 3 2 cm pressure while measuring at the point shown Belt Deflection 11 4 3 2cm Adjusting Belt Deflection P 90 1 Belt deflection on P 90 clutches is controlled by adding or removing shim washers from between the driven clutch sheaves To change belt deflection disassemble clutch as outlined on page 5 26 2 Adjust shim stack between clutches to achieve desired belt deflection At least 1 washer must remain between clutch sheave e Remove washers to decrease belt deflection Add washers to Increase belt deflection 3 Reassemble clutch as outlined on page 5 28 Adjusting Belt Deflection P 85 Belt deflection can be adjusted without removing the clutch f he j haft Used to adjust a oia belt tension One must 1 Pull belt into driven clutch to slightly open sheaves always be installed 2 Loosen three bolts on adjustment cam 3 Turn cam counterclockwise to reduce distance Optional Thin Adjustment Washer P 85 between sheaves Do not rotate past 1 position i 048 PN 7555899 4 Torque bolts to specification m Production washer is usually 075 thick with other 020 or 030 washers as required May use optional thinner 048 washer PN 7555899 if re quired to obtain proper sheave width Either the 075 or 048 washer must be installed in this location to pro
34. moved and sheave comes free 8 Remove nut from puller and set aside 9 Remove tool and bushing from puller Discard bushing 10 Remove bridge and adapter from puller Polaris Industries Inc 5 43 10 98 CLUTCHES Clutch Bushings P 85 P 85 Driven Clutch Movable Sheave Large Bushing Installation NOTE The P 85 driven moveable has a split bushing The bushing is held in place after installation by screws 11 Insert bushing PN 3569803 into clutch and tap lightly with a soft face hammer 12 Install adapter number two Item 10 onto puller See IH 5 13 Slide clutch sheave onto puller with back side away from vise 14 Turn puller barrel until rod extends past back side of sheave 15 Insert large installation tool for DU bushing Item 4 onto rod 16 Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed Adapter Number Two 17 Turn clutch sheave counterclockwise until bushing is seated 18 Remove nut from puller rod and set aside 19 Remove installation tool and slide clutch sheave from puller NOTE The screws hold the bushing in place 10 98 5 44 Polaris Industries Inc CLUTCHES Clutch Bushing P 90 Polaris 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 Dri
35. nt shift weight Perform belt to sheave clear ance adjustment with shim washers beneath spider Drive belt turn over Wrong belt for application Replace Clutch alignment out of spec Adjust alignment offset Engine mount broken or loose Inspect adjust or replace Driven clutch sheaves have excessive runout are bent or damaged Measurement should be tak en 25 in from outer circum ference on sheave face Max imum allowable tolerance is 015 6 mm Inspect replace Noise in drive system Broken drive clutch components Excessive drive clutch button tower clearance Install new buttons or shim out existing buttons Inspect replace Bearing failure chaincase jackshaft or front drive shaft Inspect adjust or replace Drive chain loose or worn sprocket teeth broken Inspect replace Driven clutch bushing worn excessively or spring broken Inspect replace Drive chain adjustment too tight too loose Inspect adjust Drive belt surface flat spots Inspect replace Over rev during initial accel eration or during heavy pulling at low ground speeds Spider roller position remaining in detent Add spider shim washers Add driven washers Reduce gear ratio chaincase models Engine bogs after engage ment Improper driven clutch setup Worn belt R
36. ol into center of clutch cover 9 With main adapter on puller insert cover onto puller rod placing outside of cover toward vise 10 Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed 11 Turn clutch cover and barrel together counterclockwise on puller rod until bushing is seated 12 Remove nut from puller rod and take installation tool and clutch cover off rod 10 98 5 48 Polaris Industries Inc P 90 Driven Clutch Moveable Sheave Bushing Removal NOTE Bushings are installed at the factory using Loc tite 680 In order to remove the bushing it will be nec essary to apply heat 13 Install main adapter Item 8 onto puller 14 Insert adapter reducer Item 9 onto puller sliding it inside the main adapter 15 Remove ramp buttons from moveable sheave 16 Using a hand held propane torch apply heat directly on bushing until tiny smoke tailings appear Clutch components will be hot In order to avoid serious burns wear some type of insulated gloves for the rest of the removal process Polaris Industries Inc 5 49 CLUTCHES Clutch Bushing P 90 Main Adapter Adapter Reducer 10 98 CLUTCHES Clutch Bushing P 90 17 Working from the top install bushing removal tool 18 Install sheave onto puller 19 Install nut onto puller rod and tighten by hand Turn 20 21 22 23 Item 5 into center of clutch sheave with smaller diameter t
37. ollowing chart will aid in the setup and balance of engine RPM power curves for special converter tuning requirements such as high operating altitude heavy loads mountainous terrain etc Drive Clutch Spring Compression Rate Chart Drive Clutch Spring Compression Rate Chart Almond 7041566 Dark Blue ww Ke 7204152 6 Dark Blue White 7041781 Blue Blue Gold 7041080 Silver Gold 7041286 ee Almond Gold J 7041645 _ _ Gold 7041148 Silver 7041062 Red 7041083 Sieve vie vier Red White 7041150 Brown 7041061 Orange 7041060 eo aoo Pink 7041065 Yellow 7041102 Green 7041168 N P N Q N S S Pac P E EEEE DEE ONA ae k D O en Purple 7041063 ESA o White ni 7041132 eee Plain 7041021 Black 7041022 a eee Blue Green 7041157 ATV only 2 50 2 25 2 00 1 75 1 50 1 25 1 19 COMPRESSED SPRING LENGTH INCHES Polaris Industries Inc 5 5 10 98 CLUTCHES Drive Clutch Spring Data PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH 125 4 2 SL e E Never shim a drive clutch spring to increase its compression rate This may result in complete stacking of the coils and subsequent clutch cover failure Maximum efficiency of the variable speed drive system is dependent upon many
38. on Converter sheaves greasy belt slippage Engine RPM above specified operating range a Incorrect drive clutch spring too high spring rate b Drive clutch shift weights incorrect for application too light c Drive clutch binding d Driven clutch binding e Converter sheaves greasy belt slippage f Improper driven clutch setup a Install proper spring b Install proper shift weights c Disassemble and clean clutch inspecting shift weights and buttons Reassemble without the spring to determine probable cause d Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location e Clean clutches install new belt f Install correct parts and or adjust t o match engine application and ma chine use Burnt Belts Premature Wear Also see Belt Wear Burning Diagnosis Chart on page 6 63 a Wrong or broken drive clutch spring b Drive clutch shift weight too heavy c Driven clutch spring broken or installed in wrong helix location d Drive belt too long e Converter sheaves greasy belt slip page f Improper driven clutch setup a Replace with recommended spring b Install correct shift weight kit to match engine application c Replace spring refer to proper installation location d install new belt and or adjust belt tension e Clean clutches install new belt
39. oval Tool 1 P 85 Driven Moveable Sheave Removal Tool P 85 Driven Moveable Sheave Removal Bridge 1 Main Puller Adapter 1 Adapter Reducer 1 Number Two Puller Adapter 1 Instruction Piston pin puller PN 2870386 Bench vise Soft face hammer for P 85 Driven Moveable Small scribe or pick for Cover Bushing Removal Hand held propane torch for P 90 Driven Loctite RC 860 Retaining Compound 2870584 Cover Bushing Inspection Garmax Style Installed Dimension Nominal Bearing Bore 1 125 28 57mm Service Limit 1 140 28 95mm Cover Bushing Inspection Teflon Bronze Style Service Limit Replace cover bushing it _ more bronze than Teflon is visible Polaris Industries Inc Nominal Bearing Bore 1 125 28 57mm Service Limit 1 132 28 75 Measure When Bushing is Installed 5 39 CLUTCHES Clutch Bushing Replacement P 85 Par No 5020627 5020628 5020629 5020630 5020631 5130862 5222768 5020632 5010279 5020633 9912260 10 98 CLUTCHES Clutch Bushing Replacement P 85 P 85 Drive Clutch Cover Bushing Removal Cont 3 On models equipped with snap ring remove round wire snap ring from inside of clutch cover using a small scribe or pick and set aside 4 Install main adapter Item 8 on puller 5 From outside of clutch cover insert removal tool Item 3 into cover bushing 6 With inside of cover toward vise slide cover onto puller 7 Insta
40. oward bushing to be removed See illustration at right Bushing Removal Tool 5 puller barrel for further tension if needed Turn clutch sheave counterclockwise until bushing is removed Repeat steps 17 20 for other bushing Remove nut from puller rod and set aside Remove adapters from puller Remove bushing and removal tool from adapters Discard bushing 10 98 5 50 Polaris Industries Inc CLUTCHES Clutch Bushing P 90 P 90 Driven Clutch Moveable Sheave Bushing Installation 24 Working from the top insert adapter number ten onto puller See illustration at right Number Ten 25 Start new bushing evenly in moveable sheave 26 Install sheave onto puller with new bushing upward as shown Install adaptor number two Polaris Industries Inc 5 51 10 98 CLUTCHES Clutch Bushing P 90 27 Install nut onto puller rod and hand tighten against installation tool 28 Turn clutch sheave counterclockwise until bushing is seated 29 Remove nut from puller rod and set aside 30 Remove installation tool and clutch sheave from puller 31 Repeat installation procedure for other moveable bushing 10 98 5 52 Polaris Industries Inc CLUTCHES Troubleshooting REMEDY Replace SYMPTOMS _ PROBABLE CAUSE Harsh drive clutch engage Drive belt worn too narrow ment Excessive belt to sheave clearance with new belt high performance version with out dete
41. retaining bolt components 6 Torque retaining bolt to specifications Hold clutch with staap wrench Drive Clutch Bolt Torque Large ID Shaft 3 4 40 45 ft Ibs 5 52 6 21 kgm Drive Clutch Bolt Torque Small ID Shaft 14mm 7 16 50 ftlbs 6 9kgm NOTE Re torque clutch to specification after first peri od of operation such as a test ride Polaris Industries Inc 5 23 L L CLUTCHES Drive Clutch 10 98 CLUTCHES Drive Clutch Spider Indexing NOTE Spider indexing affects clutch balance and belt to sheave clearance Read procedures carefully before proceeding 1 Before disassembling drive clutch mark spider cover moveable sheave and stationary sheave in line with a permanent marker as shown 2 Disassemble drive clutch as described on page 5 16 Take care to note the amount and thickness of the shim washers under the spider 3 Add or remove spider washers as required to achieve desired belt to sheave clearance e For example If belt to sheave clearance is 020 too large removing one 020 shim will position the movable sheave closer to the fixed sheave reducing belt to sheave clearance by 020 NOTE The following washers are available for fine tuning lt Washers PN5210754 050 PN 5210753 032 N 5210752 020 4 Install spider washer s and spider aligning Xs Notice as the spider seat location is changed the sheave marks made before disass
42. t for late model P 85 34 93mm systems 1997 current 3211073 1 438 12 Kad 48 375 Double cog Good for short runs on higher 36 52mm horsepower engines Drag Racers Good for lower horsepower trail riding 3211074 1 438 12 00 47 625 Double cog Good for short runs on higher 36 52mm horsepower engines Drag Racers Good for lower horsepower trail riding 3211075 1 438 28 12 00 47 625 Double cog CVT 36 52mm Belt dimensions given are nominal dimensions There is a variance for all critical dimensions Clutch set up must be inspected when a new belt is installed and If necessary clutch set up must be adjusted The drive belt is an important component of the converter system In order to achieve maximum efficiency from the converter drive belt tension deflection clutch offset and alignment must be adjusted properly General Belt Selection Guidelines NOTE Refer to appropriate parts manual for proper belt Production belt is recommended unless tuning for a specific application CVT e Increased service life for high horsepower and extended high speed running Need 1 2 grams heavier drive clutch weight e Good for prolonged high speed running e Good for aggressive riders Standard Compound More aggressive at low speeds Reduced heat and drive clutch sheave wear Used for short higher horsepower runs Drag Racing e Good trail belt for lower horsepower engines
43. tch Alignment Adjustment 1 Loosen all 4 engine mounting bolts 2 Adjust engine torque stop until clutches are in proper alignment 3 Tighten engine mounts securely 4 Recheck both clutch offset and alignment 5 Verify proper torque stop adjustment Torque Stop Adjustment NOTE There are two types of torque stops currently used Refer to the illustrations below for adjustment of each type 1 After aligning clutches adjust torque stop by loosening lock nut and rotating stop to proper clearance as shown Hold torque stop and tighten jam nut to 15 17 ft Ibs 2 07 2 35 kg m ENGINE MOUNT TORQUE STOP CRANKCASE TORQUE STOP Adjust gap between stop and engine mount to 010 030 25 75 mm 005 13 mm Nut Adjust gap between stop and engine crankcase to 100 2 5 mm 010 25 mm Polaris Industries Inc 5 37 10 98 CLUTCHES Drive Belt Belt to Sheave Clearance Inspection NOTE The distance between the belt and the moveable sheave on the drive clutch is very important This dis tance controls the starting ratio lowest starting ratio is most preferable and the position of the clutch weight to engine RPM The distance between the belt and move able sheave should be as close to 020 5 mm as pos sible without creating a drag on the belt when positioned around the hub at the bottom of the sheaves 1 Force belt to one side of drive clutch NOTE Measure total belt to sheave cl
44. to maintain proper offset alignment Polaris Industries Inc 5 25 10 98 CLUTCHES Driven Clutch Disassembly 1 Place clutch on bench CAUTION Wear eye protection during disassembly and assembly of driven clutch 2 Hold fixed sheave and turn movable sheave 1 4 turn Hold movable in place tap helix down with a soft faced hammer Remove snap ring and washer NOTE On models equipped with snap ring retainers as shown below retainer may stay on back of snap ring when clutch is removed Pry lightly to remove retainer and gain access to snap ring Refer to illustration below If retainer stays with clutch pry evenly to remove P 90 Retainer 3 Allow sheaves to return and force the helix out Before removing helix note driven clutch spring position Remove helix 4 Inspect helix ramps and movable buttons and for wear or damage P 90 driven clutch ramp buttons are secured by Torx screws P 85 buttons can be removed by applying heat to the button housing or drill button with an 1 8 drill bit The ramp buttons should be replaced when worn See Maintenance section for inspection intervals 10 98 5 26 Polaris Industries Inc CLUTCHES Driven Clutch Disassembly Cont 5 Remove driven clutch spring Both spring tabs should line up If not spring is fatigued and should be replaced Tabs Aligned 6 Slide moveable sheave off and inspect sheave surfaces for wear or grooving
45. unterclockwise and releasing Sheave should open and close smoothly with a positive stop Some helix ramps have more than one washer beneath the snap ring Refer to page 6 37 for more information 10 98 5 30 Polaris Industries Inc Installation 1 Install proper number of spacer washers on jackshaft between clutch and jackshaft bearing Inspect Jackshaft Bearing Excessive vibration or abnormal drive belt wear can be caused by a worn bearing or jackshaft on the driven clutch side To inspect bearing fit watch the bearing area closely as you try to force the jackshaft up and down If movement is detected disassemble to determine which parts are worn Replace the jackshaft if the new bearing is loose on the shaft The bearing should be greased at 1000 mile 1600 km intervals and before storage NOTE Spacer washers between driven clutch and jack shaft bearing set the offset Refer to adjustment proce dure on page 5 36 to adjust offset between the drive and driven clutch 2 3 Lightly grease jackshaft keyway or spline With square key in place P 85s slide clutch onto jackshaft Install spacer bolt and washer to hold driven clutch in place Driven Clutch Retaining Bolt Torque 15 ft Ibs 2 08 kg m 4 P 85 and P 90 driven clutches should float from side to side 040 080 1 2 mm Without a slight free float jackshaft bearings could be side loaded causing premature bearing failure NOTE
46. ven Clutch Bushing Removal Tool 5020631 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 10 1 Number Two Puller Adapter 5020633 P 90 Drive Clutch Moveable Sheave Bushing Removal Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing 1 Install handle end of piston pin puller securely into bench vise and lightly grease puller threads 2 Remove nut from puller rod and set aside 3 Install main adapter Item 8 onto puller Piston Pin Puller PN 2870386 Main Adaptor 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 nut removed in step 2 onto end of puller rod and hand tighten Turn puller barrel to increase tension on sheave if needed Nut is left hand thread Polaris Industries Inc 5 45 10 98 CLUTCHES Clutch Bushing P 90 6 Turn sheave and puller barrel together counterclockwise on puller rod until bushing is removed 7 Remove nut from puller rod and set aside 8 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Drive Clutch Moveable Sheave Bushing Installation 9 Place main adapter Item 8 on puller 10 Push bushing into center of sheave on tower side by hand Bushing PN 3576504 11 Insert installation tool Item 2 into center of sheave and with towers pointing away from
47. vide support for the adjustment Polaris Industries Inc 5 35 10 98 CLUTCHES Drive Belt Clutch Offset Inspection NOTE Proper offset aligns the fixed sheaves of both Offset Non Electric Start Models clutch assemblies This allows the clutches to be _ A 21 32 Offset aligned throughout the shift range ov No gap at All models with P90 ar oint A i 1 Remove drive belt Belt deflection adjustments si P driven clutch affect offset Set belt deflection first Sy 5 8 Offset All models with P85 driven clutch 2 Install proper alignment tool depending on type of clutch as shown in Ill 1 3 Rear of driven clutch moveable sheave should just contact tool when clutch is pushed inward on jackshaft NOTE Up to 060 1 5mm air gap allowed at point B Up to 125 is acceptable on new machines Clutch Alignment T ools i P90 21 32 Offset PN 2870914 P85 5 8 Offset PN 2870426 P90 Electric Start 1 28 Offset straight edge P85 Electric Start 1 Offset straight edge Clutch Offset Adjustment l Onset elignmene Toe 1 Determine direction driven clutch needs to be adjusted Refer to Clutch Offset Inspection procedure above 2 Remove driven clutch retaining bolt and remove Offset Electric Start Models driven clutch NOTE Up to 060 1 Smm 3 Add or take out washers on jackshaft between the MI Eee Sac driven clutch and jackshaft bearing to a
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