Clutching - ASAP All Terrain
Contents
1. 2 Drive and Driven Clutch Buttons and Bushings Drive Clutch Shift Weights and Pins Drive Clutch Spider Rollers and Roller Pins Drive and Driven Clutch Springs 3 Sheave Faces Clean and inspect for wear 4 PVT System Sealing Refer to appropriate illustrations on the following pages The PVT system is air cooled by fins on the drive clutch stationary sheave The fins create a low pressure area in the crankcase casting drawing air into the system through an intake duct The opening for this intake duct is located at a high point on the vehicle location varies by model The intake duct draws fresh air through a vented cover All connecting air ducts as well as the inner and outer covers must be properly sealed to ensure clean air is being used for cooling the PVT system and also to prevent water and other contaminants from entering the PVT area This is especially critical on units subjected to frequent water forging 6 3 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Overheating Diagnosis During routine maintenance or whenever PVT system overheating is evident it s important to check the inlet and outlet ducting for obstructions Obstructions to air flow through the ducts will significantly increase PVT system operating temperatures The vehicle should be operated in Low when plowing or pulling heavy loads or if extended low speed operation is anticipated2. Clutch Alignment Tool PA 49011 6 10 8 As you rotate the tool down between the drive clutch sheaves the tool should touch the clutch shaft bearing while maintaining a clearance of roughly 020 between the tool and stationary sheave of the drive clutch Stationary Sheave i 9 Ifthe alignment tool hits the stationary sheave before it reaches the shaft bearing the driven clutch will need to be spaced out to correct the offset e Remove the driven clutch Add the required amount of offset washers to obtain the correct measurement with the alignment tool You may need to add more than one offset washer Offset Washers 030 PN 7556454 060 PN 7556120 10 If the alignment tool touches the shaft bearing but has an excessive amount of clearance between the tool and stationary sheave the driven clutch will need to be moved in to correct the offset e Remove the driven clutch Remove the required amount of washers to obtain roughly 020 clearance between the tool and stationary sheave NOTE The number of washers behind the driven clutch will vary between vehicles IMPORTANT It may not be possible to achieve perfect offset with the tool as previously described because of the thickness of the offset washers It is better to have clearance between the tool and stationary sheave of the drive clutch than to have the tool touch the stationary sheave before it touches the shaft bearin
3. 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt Setting Center To Center Distance 2 Inspect belt for loose cords missing cogs cracks abrasions thin spots or excessive wear Compare belt measurements with a new drive belt Replace if necessary 3 Belts with thin spots burn marks etc should be replaced to eliminate noise vibration or erratic PVT operation See the troubleshooting chart at the end of Distance this chapter for possible causes 10 05 in 255 mm Belt Installation Clutch center distance is controlled by the correct positioning of the engine and transmission mounting The 10 Center Distance Tool PN 2871710 should be used for the following NOTE Be sure to install belt in the same direction as it was removed 1 With the belt removal tool installed PN 2877408 loop the belt over the drive clutch and over the driven clutch e After engine installation After transmission installation After engine or transmission mount replacement If the vehicle exhibits drive clutch drag or hard shifting while at idle speed after clutch offset adjustment has been performed Secondary Shaft Primary Shaft 2871710 2 Rotate the driven clutch and walk the belt into the clutch 3 Remove the belt removal tool from driven clutch
4. CLUTCH DRIVE BELT amp COVER RELATED ISSUES DIAGNOSIS Possible Causes Solutions What to do Loading the vehicle into a truck or tall Shift transmission to Low during loading of the vehicle to prevent belt trailer when in high range burning Starting out going up a steep incline from ne When starting out on an incline shift the transmission to Low a stopped position Driving at low RPM or low ground speed Drive at higher speed or use Low The use of Low is highly recommended at approximately 3 7 MPH for cooler PVT operating temperatures and longer component life Warm engine at least 5 min then with transmission in neutral advance throttle to approx 1 8 throttle in short bursts 5 to 7 times The belt will become more flexible and prevent belt burning Insufficient engine warm up when exposed to low ambient temperatures Slow and easy clutch engagement Fast effective use of the throttle for efficient engagement Towing Pushing at low RPM low ground speed Use Low only Plowing snow dirt etc utility use Use Low only Shift the transmission to Low carefully use fast aggressive throttle Stuck in mud or snow application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to Low carefully use fast aggressive brief throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehi
5. Manual Copyright 2011 Polaris Sales Inc CLUTCHING 13 Inspect the bearing for wear Spin the bearing if the bearing does not spin smoothly replace it To replace the bearing remove the snap ring from the end of the shaft and press the bearing off the shaft Press shaft and bearing out as an assembly Inspect Bearing Remove snap ring if replacing bearing 14 Inspect the cam helix assembly bushing for wear If the bushing is worn or the shaft does not fit snug into the bushing replace the cam helix assembly 15 Inspect the clutch sheaves for excessive wear or damage Inspect Sheave Surface 6 28 Bushing Service IMPORTANT Special Tools Required EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing Removal 5132028 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool 2871226 1 Piston Pin Puller 2870386 Clutch Bushing Replacement Tool Kit PN 2871226 Part Item Qty Part Description P 90 Drive Driven Clutch ie Bushing Install Tool 5020628 Drive Clutch Cover Bushing Removal is l Installation Tool SRAD EE all clutches P 90 Driven Clutch Cover 9 Bushing Removal Tool 9020691 8 1 Main Puller Adapter 502
6. Nm pring Bearing QU de 9 Bolt 47 ft Ibs 64 Nm Non EBS A LA Non Braking Bearing NA NN Flat Bearing AN Cover Washer INES Button Spacer Screws EBS FAS Ne 90 in lbs ae Roller g UN NY Fy x 10 Nm Nut Washers Button Or oor Shift Weight Washers Shift Weights Shown below are the shift weights which have been designed for this PVT system These shift weights have many factors designed into them for controlling engagement RPM and shifting patterns Shift weights should not be changed or altered without first having a thorough understanding of their positioning and the effects they may have on belt to sheave clearance clutch balance and shifting pattern PN 1322915 PN 1322914 PN 1322911 PN 5632337 Bushed Weight Bushed Weight Bushed Weight 6 14 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Clutch Disassembly 5 Inspect area on shaft where bushing rides for wear galling nicks or scratches Replace clutch assembly if worn or damaged LE r 1 Using a permanent marker mark the cover spider and moveable and stationary sheaves for reference as the cast in X s may not have been in alignment before disassembly 6 Remove and inspect the clutch spring See Drive Clutch Spring Specifications for spring inspection 2 Mark the stationary sheave and clutch shaft to verify the shaf
7. inspect to see if roller and bushing are separating Bushing must fit tightly in roller Use the Roller Pin Tool PN 2870910 to replace rollers and pins Take care not to damage roller bushing or bearing surface of the new pin during installation 2 Rubber backed buttons can be used in all RANGER clutches if the hollow roller pin is changed to the solid roller pin NOTE The rubber side of the button is positioned toward the solid roller pin 6 18 e Clutch Inspection NOTE Remove cover spring and spider following instructions for drive clutch disassembly then proceed as follows Remove the moveable sheave spacer A Inspect for damage or wear Remove the moveable clutch sheave B Inspect for damage or wear Lift bearing C and PTFE washers D off the shaft Replace as an assembly if worn damaged or if problems were noted 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 4 Inspect surface of shaft for pitting grooves or Moveable Sheave Bushing Inspection damage Measure the outside diameter and compare to specifications Replace the drive clutch assembly Inspect the Teflon coating arrow on the moveable if shaft is worn or damaged sheave bushing Inspect both sheaves for signs of wear grooving or cracking De glaze sheave surfaces with a 3M Scotch Brite Pad if needed Y ym In mm Moveable Sheave Bushing Inspectio
8. to service Due to the severe relaxation the spring is subject to during operation it should always be inspected for tolerance limits during any clutch operation diagnosis or repair With the spring resting on a flat surface measure its free length from the outer coil surfaces Also check to see that spring coils are parallel to one another Distortion of the spring indicates stress fatigue requiring replacement Drive Clutch Spring Specifications Part Number 7043594 Color Black Free Length 2 80 in 7 11 cm 6 16 Shift Weight Inspection 1 Remove shift weight bolts and weights Inspect the contact surface of the weight The surface should be smooth and free of dents or gall marks Inspect the weight pivot bore and bolts for wear or galling If weights or bolts are worn or broken replace in sets of three with new bolts and nuts Inspect for excessive wear Inspect for excessive wear Inspect for excessive wear A WARNING The clutch assembly is a precisely balanced unit Never replace parts with used parts from another clutch assembly NOTE A damaged shift weight is usually caused by a damaged or stuck roller in the spider assembly See Roller Pin and Thrust Washer Inspection 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Button To Tower Clearance Inspection NOTE To maintain proper clutch balance and belt
9. wrong helix location Replace with recommended spring Install correct shift weight kit to match engine application Replace spring refer to proper installation location Erratic engine operating RPM during acceleration or load variations Drive clutch binding Belt worn unevenly thin burnt spots Driven clutch malfunction Sheave face grooved A Disassemble drive clutch inspect shift weights for wear and free operation B Clean and polish stationary shaft hub reassemble clutch without spring to determine problem area Replace belt A Replace ramp buttons B Inspect movable sheave for excessive bushing clearance Replace the clutch Engine RPM above specified operating range Incorrect drive clutch spring too high of rate Drive clutch shift weights incorrect for application too light Drive clutch binding Driven clutch binding Converter sheaves greasy belt slipage Install correct recommended spring Install correct recommended shift weights Disassemble and clean clutch inspecting shift weights and rollers Reassemble without the spring and move sheaves through entire range to further determine probable cause Disassemble clean and inspect driven clutch noting worn sheave bushing and ramp buttons and helix spring location Clean sheaves with denatured alcohol or brake cleaner install new belt Harsh drive clutch engagement Driv
10. 0632 9 1 Adapter Reducer 5010279 10 4 Number Two Puller 5020633 Adapter NOTE Bushings are installed at the factory using Loctite 609 In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from bushing bore prior to installing new bushing 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc CLUTCHING Clutch Bushing Removal 1 Install main puller adapter Item 8 onto puller 2 Install adapter reducer Item 9 8 Using a hand held propane torch apply heat around outside of bushing until tiny smoke tailings appear 4 Flip sheave over so bushing faces downward and install onto puller 5 Install bushing tool Item 2 EBS Driven Clutch Outer Bushing Removal Bushing Tool 2 A Nut C L Adapter Reducer 9 Main Adapter 8 6 Install left hand nut C and spacer onto puller rod and tighten by hand Turn puller barrel for further tension if needed 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 10 Remove bushing and removal tool from adapters Discard bushing 4 Install sheave face down on puller 5 Install new bushing on installation tool Item 2 and Clutch Bushing Installation 1 Install pulle
11. 4 Rotate spin the driven clutch and belt approximately 5 7 times to properly seat the belt in the driven clutch 5 Install the outer clutch cover and 8 screws Torque screws to specification Outer Clutch Cover Retaining Screws 45 50 in Ibs 5 5 Nm 6 9 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING CLUTCH OFFSET NON EBS Clutch Offset Procedure Alignment Tool Clutch offset is controlled by the number of washers that are placed behind the driven clutch on the transmission input shaft Adding washers behind the driven clutch will move the drive belt toward the moveable sheave Removing washers will move the belt toward the stationary sheave If the vehicle exhibits drive clutch drag or hard shifting while at idle speed a clutch offset adjustment is required 1 Remove the lower seat base 2 Remove the LH storage container to gain access to the outer PVT cover 3 Loosen the hose clamps and remove the PVT air outlet duct hose from the outer PVT cover 4 Remove all outer PVT cover screws and cover Mark the drive belt direction of rotation and remove it Refer to DRIVE BELT NON EBS Belt Removal 6 Install the Clutch Alignment Tool CLUTCH ALIGNMENT TOOL PA 4901 1 7 Place the alignment tool in the sheaves of the driven clutch and hold firmly as you rotate it down between the sheaves of the drive clutch 5 gt
12. CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES ere sa a O Eee ee 6 2 TORQUE SPECIFICATIONS ces si wate when we anne pue se art DES 6 2 HIGH ALTITUDE CLUTCA GHAR TS 28a Ie ts Oe a he 6 2 PVT SYSTEM OVERVIEW sro aia ai tri dae e rl vda ase Bekele ate 6 2 GENERAL OPERATION dsc os a 6 2 DRIVE DRIVEN CLUTCH OPERATION 6 3 PVT BREAK IN DRIVE BELT CLUTCHES 6 3 MAINTENANCE INSPECTION 6 3 OVERHEATING DIAGNOSIS 6 4 PVT SYSTEM SERVICE rai insect Panne o D ea al A Apia 6 5 PVT SEALING GUARD AND DUCTING COMPONENTS 6 5 DISASSEMBLY gt conta rita rato arca rio 6 5 NS IIA AA CAE A A 6 6 DRIVE BELF NONsEBS oras rata a Ao 6 7 BELT REMOVAL INSPECTION ld 6 7 BELT INSTALLATION varita ta ee 6 8 DRIVEBELTIEBS IS ass naaa aa 6 8 BEDMREMOWAL A ui ne send eet nd fees Sine gaunt pda cent og be 6 8 BELT INSPECTION INSTALLATION 52 seen sew ire mate tte 6 9 GLUTCH CENTER DISTANCE sos genie dice nets Bard ace ose ee geste dt wa nie 6 9 CLUTCH OFFSET NON EBS este wiry tt pei 6 10 CLUTCH OFFSET EBSj A CR LR ete AT eats 6 12 DRIVE CLUTCH SERVICE que ecos dao a e ea anne sed 6 14 EXPLODED VIEW SHIFT WEIGHTS 6 14 CLOTCHIDIS ASSEMBLER 6 15 BEARING INSPECTION sci usanvesacdec oia 6 15 DRIVE CLUTCH SPRING I
13. LUTCHING 5 Install the roller pin into the sheave assembly on both 9 Install the spider dampener G inside the outer spider sides The flat side of the roller pin faces downward and install the inside spider plate H when the shaft side is laying flat on the bench Flat Side Down _ DA 10 Install the spider assembly onto the shaft with the 6 Install the spring pins C to secure the roller pins retaining ring on top of the spider NOTE Use the Install until flush with sheave surface marks previously made to align the skip tooth spider or use the X on top of the spider and align it with the skip tooth on the shaft 7 11 Place the driven clutch into the Universal Clutch Compressor PU 50518 PU 50518 8 Install the clutch rollers D onto each side of the outside spider Install the washers E and E clips F to secure the rollers The rollers should spin freely 6 31 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 12 Press down on the top of the spider assembly 14 Install the cam helix assembly over the shaft Line pushing the spider onto the shaft up the X on the cam X on spider and X on the stationary sheave or use the marks previously made before disassembly NOTE If the cam assembly helix is difficult to install be sure the sheaves are aligned To align the sheaves place the clutch assem
14. NSPECTION 6 16 SHIFT WEIGHT INSPECTION 6 16 BUTTON TO TOWER CLEARANCE INSPECTION 6 17 SPIDER REMOVAL con ies cud adi s 6 17 ROLLER PIN AND THRUST WASHER INSPECTION 6 18 CLUTCH INSPECTION Say trust arabe 6 18 MOVEABLE SHEAVE BUSHING INSPECTION 6 19 BUSHING SERVICE nn a chr queen re nier 6 20 CLUTCH ASSEMBLY ut pan eue un ne nie ad 6 22 DRIVEN CLUTCH SERVICE NON EBS 6 23 EXPLODED VIEW aide de rad aia cto 6 23 CLUTCH DISASSEMBLY INSPECTION 6 23 CIUTCH ASSEMBLY 22 nc asl nie dan ocu 6 25 DRIVEN CLUTCH SERVICE EBS 28e 40 ut rs pates aie matt 6 26 CLUTCH DISASSEMBLY 5 2 remaniement me be 6 26 BUSHING SERVICE aai E eles uh me Witt Ih acl mentee ate ome 6 28 CLUTCH ASSEMB Carina irrestricto 6 30 EXPLODED VIEW desidia ne RU LA en ie td Cr A det 6 33 TROUBLESHOOTING earth ras 6 34 6 1 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING SPECIAL TOOLS AND SUPPLIES TOOL DESCRIPTION PART NUMBER Clutch Alignment Tool Non EBS PA 49011 Clutch Bushing Replacement 2871025 Tool Kit Clutch Bushing Replacement 2871226 Tool Kit Clutch Holding Fixture 2871358 A Clutch Holding Wrench 9314177 Dri
15. al Wear 8 Check the rollers in the stationary sheave for wear If rollers are worn a new driven clutch assembly may be needed Check Rollers for Wear Check Rollers or Wear 9 Inspect the bearings inside the moveable sheave er mn y Inspect Bearings for Wear WA Moveable Sheave Bearing Inspection Replace the bearing if more brass than Teflon is visible on the bearing 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 10 Inspect driven clutch sheave faces for wear or damage ED 11 Clean and inspect splines on helix and transmission input shaft D 12 Lube splines with a light film of grease Do not lubricate the bearings Ah Clutch Assembly 1 Install the inner spring retainer if removed Do not apply oil or grease to the bearings pS Assemble Sheaves wm Install spring into inner retainer A Install outer retainer on top of spring 2 Align the X marks on each of the sheaves during reassembly 5 Place the driven clutch into the Universal Clutch Compressor PU 50518 6 Apply and hold downward pressure on the outer spring retainer Carefully install the snap ring oe Ring 6 25 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING DRIVEN CLUTCH SERVICE EBS Clutch Disassembly 1 Remove driven clutch from the transmission input
16. bly on a flat surface with the cam assembly helix side down Press down on the moveable sheave belt face with both hands and the helix will release Press down on spider Press Down to Loosen Helix 15 Use a T25 Torx driver to install the four helix retaining screws a nd torque to specification 13 Slowly compress the spider into place If the spider a a gt appears to bind while compressing stop and make E C T sure the skip tooth on the shaft and the spider are E aligned Once the spider passes the retaining ring Do 5 notch on the shaft install the retaining ring Helix Retaining Screws 42 52 in Ibs 4 75 5 88 Nm 6 32 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Exploded View T25 Screws 42 52 in lbs 4 75 5 88 Nm Compression Spring Cam Helix Retaining Q Moveable 4 Sheave Outer Roller Spider Spider 4 Insert Clutch Shaft Slotted Spring Pin Retaining Ring Stationary Sheave Ball Bearing 6 33 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING TROUBLESHOOTING Situation Probable Cause Remedy Engine RPM below specified operating range although engine is properly tuned Wrong or broken drive clutch spring Drive clutch shift weight too heavy Driven clutch spring broken or installed in
17. cle overturn Climbing over large objects from a stopped position Shift the transmission to neutral Using the throttle vary the engine rpm from Belt slippage from water or snow idle to full throttle Repeat several times as required During this procedure ingestion into the PVT system the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs For inspection of clutch components please contact your Polaris dealer Clutch malfunction Shift transmission to Low during loading of the vehicle to prevent belt burning Fouled plugs foreign material in gas tank fuel lines or carburetor Contact Poor engine performance Me f gine p you dealer for further service information Low Heavy pulling basic operational speeds less than 7 MPH riding GENERAL RANGE OPERATION through rough terrain swamps mountains ect low ground speeds GUIDELINES High High ground speeds speeds above 7 MPH Operating in Low Gear Low gear is the primary driving gear range for RANGERS Low should be used in ALL driving applications except for driving on hard packed level surfaces with light loads In this circumstance High range may be used IMPORTANT Using High range for heavy loads hilly terrain or in wet muddy conditions will increase the chance of drive belt burning 6 4 9923499 2011 2012 RANGER 800 Service Manua
18. e belt worn too narrow Excessive belt sheave clearance with new belt Replace belt Perform belt sheave clearance adjustment with shim washers beneath spider Drive belt turns over Wrong belt for application Clutch alignment out of spec Engine mount broken or loose Replace with correct belt Adjust clutch alignment Inspect adjust or replace Belt burnt thin spots Abuse continued throttle application when vehicle is stationary excess load Dragging brake Slow easy clutch engagement Caution operator to operate machine within guidelines Vehicle operated with park brake on Inspect brake system Fast effective use of throttle for efficient engagement 6 34 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Troubleshooting Continued Situation Probable Cause Remedy PVT cover overheating melting Plugged air intake or outlet Belt slippage due to water oil grease etc rubbing on cover Clutches or weight being applied to cover while in operation High vs low range Clear obstruction Inspect system Clean repair or replace as necessary Seal PVT system ducts Remove weight Inform operator Instruct operator on guidelines for operation in proper driving range for different terrain as outlined in Owner s Safety and Maintenance Manual Water
19. earing 2 Install the moveable sheave and spacer onto the clutch shaft NOTE To maintain proper clutch balance and belt to sheave clearance be sure to reinstall the original quantity and thickness of washers spacers beneath the spider during assembly Spacer Washers Spider Bearing 6 22 Compress spider buttons for each tower and install spider making sure that X or the marks that were made earlier on the spider aligns with X or the marks that were made earlier on the moveable sheave Torque spider to specification using the holding fixture and spider tool Torque with smooth motion to avoid damage to the stationary sheave e T Spider Torque 200 ft Ibs 271 Nm After the spider has been torqued remove the clutch assembly from the holding fixture and inspect the shaft and sheave alignment marks made during disassembly IMPORTANT If the marks are no longer in alignment the clutch will not be in balance and the drive clutch assembly must be replaced Install shift weights using new lock nuts on the bolts rss Nut on trailing side Reinstall clutch spring Reinstall cover making sure that X or the marks that were made earlier the on spider aligns with X or the marks that were made earlier on the cover Torque cover bolts evenly to specification E T Cover Screw Torque 90 in Ibs 10 4 Nm 9923499 2011 2012 RANGER 800 Serv
20. eave clearance If belt is making contact with either sheave remove drive belt Clutch Offset Procedure and driven clutch Refer to DRIVE BELT EBS Belt Removal Clutch offset is controlled by the number of washers that are placed behind the driven clutch on the transmission input shaft Adding washers behind the driven clutch will move the drive belt toward the moveable sheave Removing washers will move the belt toward the stationary sheave If the vehicle exhibits drive clutch drag or hard shifting while at idle speed a clutch offset adjustment is required 1 Remove the lower seat base 2 Remove the LH storage container to gain access to the outer PVT cover 3 Loosen the hose clamps and remove the PVT air outlet duct hose from the outer PVT cover 7 Add or remove offset washers behind the driven clutch accordingly to avoid belt contact with either 4 Remove all outer PVT cover screws and cover drive clutch sheave CAUTION Do not start the engine with the outer clutch cover removed Serious injury may result 5 Rotate driven clutch counterclockwise several times to ensure belt is tight and riding at the proper height Offset Washers 030 PN 7556454 060 PN 7556120 6 12 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 8 Reinstall the driven clutch and drive belt Torque the 12 Position the PVT air o
21. g 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 11 After completing the clutch offset procedure the belt should ride in the drive clutch with an approximate 020 gap between the belt and stationary sheave and a larger gap of approximately 130 between the belt and moveable sheave There should always be clearance on both sides of the drive belt T a Donotstartthe engine with the outer clutch cover CAUTION removed Serious injury may result Inspect the outer clutch cover gasket Replace if damaged Install the outer clutch cover and 8 screws Torque screws to specification e T Outer Clutch Cover Retaining Screws 45 50 in Ibs 5 5 Nm Position the PVT air outlet duct hose and tighten the hose clamps Install the LH storage container and lower seat base Sit in the drivers seat apply the brake and start the engine Place the gear selector in high range and test the vehicle for drive clutch drag or hard shifting while at idle speed If shifting remains difficult refer to CLUTCH CENTER DISTANCE to check positioning of the engine and transmission mounting CAUTION Do not leave the vehicle unattended 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc 6 11 CLUTCHING CLUTCH OFFSET EBS 6 Inspect drive clutch belt to sh
22. h cover and secure with SYSTEM SERVICE Disassembly screws Torque screws to specification 2 Mark the drive belt direction of rotation so that it can 16 Install the PVT cover outlet duct and tighten the be installed in the same direction clamps NOTE Belt is normally positioned so that part numbers are easily read 3 To remove drive belt put transmission in gear apply brake pull upward and rearward on belt to open driven clutch sheaves Inner Cover Screw Torque Front Screws 50 in Ibs 5 6 Nm Rear Screws 12 ft Ibs 16 Nm Outer Cover Screw Torque 45 50 in Ibs 5 5 6 Nm 4 Pull out and down on the drive belt to slip over the driven clutch outer sheave Driven Clutch Retaining Bolt Torque 17 ft Ibs 23 5 Nm Drive Clutch Retaining Bolt Torque 47 ft Ibs 64 Nm 5 Slip belt over the drive clutch outer sheave and remove the belt from the vehicle Belt Inspection 1 Inspect belt for hour glassing extreme circular wear in at least one spot and on both sides of the belt Hour glassing occurs when the drive train does not move and the drive clutch engages the belt 6 7 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 2 Inspect belt for loose cords missing cogs cracks DRIVE BELT EBS abrasions thin spots or excessive wear Compare belt measurements with a new drive belt Replace if Belt Removal necessary
23. hill and downhill and throttle settings are constant the drive and driven clutches are continually shifting to maintain optimum engine RPM At full throttle a perfectly matched PVT system should hold engine RPM at the peak of the power curve This RPM should be maintained during clutch upshift and backshift In this respect the PVT system is similar to a power governor Rather than vary throttle position as a conventional governor does the PVT system changes engine load requirements by either upshifting or backshifting PVT Break In Drive Belt Clutches A proper break in of the clutches and drive belt will ensure alonger life and better performance Break in the clutches and drive belt by operating at slower speeds during the 10 hour break in period as recommended see Chapter 3 Engine Break In Period for break in example Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period Maintenance Inspection Under normal use the PVT system will provide years of trouble free operation Periodic inspection and maintenance is required to keep the system operating at peak performance The following list of items should be inspected and maintained to ensure maximum performance and service life of PVT components Refer to the troubleshooting checklist at the end of this chapter for more information 1 Belt Inspection Drive to Driven Clutch Alignment and Clutch Center Distance
24. hing With inside of cover toward vise slide cover onto puller Install nut onto puller rod and hand tighten Turn puller barrel to increase tension as needed Turn clutch cover counterclockwise on puller rod until bushing is removed and cover comes free Remove nut from puller rod and set aside Remove bushing and bushing removal tool from puller Discard bushing Cover Bushing Installation 1 2 Apply Loctite 609 evenly to bushing bore in cover Working from inside of cover insert new bushing and bushing installation tool into center of clutch cover With main adapter on puller insert cover onto puller rod placing outside of cover toward vise Install nut on rod and hand tighten Turn puller barrel to apply more tension if needed Turn clutch cover counterclockwise on puller rod until bushing is seated Remove nut from puller rod Take installation tool and clutch cover off rod 6 21 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Clutch Assembly NOTE The Teflon bushings are self lubricating CAUTION Do not apply oil or grease to the bushings Reassemble the drive clutch in the following sequence Be sure the X or the marks that were made earlier are aligned during each phase of assembly 1 Install the fiber washers and bearing over the clutch shaft There should be one fiber washer on each side of the b
25. ice Manual Copyright 2011 Polaris Sales Inc CLUTCHING DRIVEN CLUTCH SERVICE NON EBS Exploded View Compression Spring Outer Spring Retainer ae Inner Spring Retainer Pi Ring 0 Moveable Inner Sheave Secondary Stationary Sheave Clutch Disassembly Inspection 3 Place the driven clutch into the Universal Clutch Compressor PU 50518 Apply and hold downward pressure on the outer spring retainer Carefully A CAUTION remove the snap ring Remember the outer spring retainer contains strong spring pressure Wear eye protection when removing snap ring to prevent serious personal injury sy Use caution when removing the snap ring gt y pressure is loaded by the compression spring E D 1 Remove driven clutch from transmission input shaft 2 Mark position of clutch sheaves before disassembly or use the X s on the sheaves for reference This aids in reassembly and maintains clutch balance after reassembly NOTE Spring is compression only and has no torsional wind 6 23 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 4 With the snap ring A removed and spring pressure relieved remove the outer spring retainer B compression spring C and inner spring retainer D 6 Inspect the helix on the moveable sheave 6 24 7 Inspect the inner spring retainer for wear and replace as needed a TU Inspect for Abnorm
26. ingestion Cover seals or ducts leaking Operator error Find leak and repair as necessary Instruct operator on guidelines for operation in wet terrain as outlined in Owner s Safety and Maintenance Manual Belt worn out Replace belt erratic or stabby Belt slippage Water ingestion Inspect and seal PVT system Belt contaminated with oil or grease Inspect and clean Belt worn or separated thin spots loose belt Replace belt EROS Broken or worn clutch components cover hitting Inspect and repair as necessary clutches Thin spots on belt worn belt Replace belt Refer to belt burnt troubleshooting and Engagement instruct operator Drive clutch bushings stick Inspect and repair clutches 6 35 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING NOTES 6 36 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc
27. l Copyright 2011 Polaris Sales Inc CLUTCHING PVT SYSTEM SERVICE PVT Sealing Guard and Ducting Components Inner Cover Retainer Screws 12 ft lbs 16 Nm Inner Cover Seal y Screws O IFA a 50 in Ibs GL 5 6 Nm Outer Cover Seal Clamps se Outer PVT Cover Clutch Outlet Duct Disassembly Some fasteners and procedures will vary Refer to the 5 Install the Drive Clutch Holder PN 9314177 A appropriate parts manual for proper fasteners and fastener placement 6 Remove drive clutch retaining bolt and remove drive clutch using the Drive Clutch Puller PN 2870506 B 1 Remove seat and storage container to gain access to the PVT outer cover Drive Clutch Puller PN 2870506 2 Remove PVT air outlet duct hose Drive Clutch Holder PN 9314177 3 Remove outer PVT cover screws 4 Mark the drive belt direction of rotation and remove 7 Remove driven clutch retaining bolt and driven clutch drive belt See Drive Belt Removal 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc CLUTCHING 8 Remove the driven clutch alignment washer s from 3 Apply RTV silicone sealant to outside edge of inner the transmission input shaft cover to engine seal to ensure a water tight fit between the seal and the cover Surfaces must be clean to ensure adhesion Note Number of Washers 4 Reinstall cover and tighten rear cover bolts just enough
28. l 1 Remove outer PVT cover as described in PVT 3 Belts with thin spots burn marks etc should be SYSTEM SERVICE Disassembly replaced to eliminate noise vibration or erratic PVT operation See the troubleshooting chart atthe endof 2 Mark the drive belt direction of rotation so that it can this chapter for possible causes be installed in the same direction Belt Installation NOTE Belt is normally positioned so that part numbers are easily read NOTE Be sure to install belt in the same direction as it was removed 3 Insert the belt removal tool PN 2877408 into the driven clutch as shown tool included with vehicle s tool kit 1 Loop belt over drive clutch and over driven sheave 2 While pushing down on top of belt turn the back or moveable driven sheave clockwise NOTE Make sure the tool is square with the moveable sheave surface of the driven clutch 4 Rotate the tool towards the clutch to open the sheaves 3 The belt then should be able to be pushed down into and between the sheaves 4 Install the outer clutch cover and 8 screws Torque screws to specification 5 Walk the belt out of the driven clutch and drive clutch eS T Remove the belt from the vehicle Outer Clutch Cover Retaining Screws 45 50 in Ibs 5 5 Nm 6 8 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Belt Inspection CLUTCH CENTER DISTANCE
29. l FOR AeS Drive Clutch Cover Bushing Removal a l Installation Tool S0F OBS all clutches P 90 Driven Clutch Cover AS l Bushing Removal Tool NE 8 1 Main Puller Adapter 5020632 9 1 Adapter Reducer 5010279 Number Two Puller 10 1 Adapter 5020633 bushing bore prior to installing new bushing 6 20 Clutch components will be hot In order to avoid CAUTION serious burns wear insulated gloves during the removal process Moveable Sheave Bushing Removal 1 2 4 5 6 7 Remove clutch as outlined previously in this chapter Install handle end of the Piston Pin Puller PN 2870386 securely into bench vise and lightly grease puller threads Piston Pin Puller PN 2870386 Remove nut from puller rod and set aside Piston Pin Puller PN 2870386 Main Puller Adaptor 8 PN 5020632 Install main adapter Item D onto puller lt ee DT A Nut C F PE NETA ALO PistonPin Main Adapter D Puller With towers pointing toward the vise slide sheave onto puller rod Install removal tool Item A B into center of sheave with A side toward sheave 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc CLUTCHING NOTE Use Bushing Tool PA 47336 8 10 11 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 pro
30. ld 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 spin ning 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 resis tance at the transmission input shaft is greater than the load from the drive belt the drive belt is kept at the outer diameter of the driven clutch sheaves As engine RPM and horsepower increase the load from the drive belt increases resulting in the belt rotating up toward the outer diameter of the drive clutch sheaves and downward into the sheaves of the driven clutch This action which increases the driven clutch speed is called upshifting Should the throttle setting remain the same and the vehicle is subjected to a heavier load the drive belt rotates back up toward the outer diameter of the driven clutch and downward into the sheaves of the drive clutch This action which decreases the driven clutch speed is called backshifting In situations where loads vary such as up
31. n Replace the cover bushing if more brass than Teflon is visible on the bushing Refer Shaft Diameter to Bushing Service in this chapter Standard 1 3745 1 375 34 91 34 93 mm Service Limit 1 3730 34 87 mm 5 Visually inspect PTFE thrust washers for damage Measure the thickness and compare to specification Replace if worn or damaged l lt X Im mm PTFE Washer Thickness Standard 030 76 mm Service Limit 025 64 mm aol le 6 19 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Bushing Service IMPORTANT Special Tools Required EBS Clutch Bushing Tool Kit 2201379 Item Qty Part Description Part A B 1 EBS Puller Tool 5132027 C 1 EBS Puller Nut 5132501 D 1 EBS Main Adapter 5132029 E 1 EBS Bushing Removal 5132028 e 1 Instructions 9915111 Additional Special Tools Qty Part Description Part 1 Clutch Bushing Replacement Tool 2871226 1 Piston Pin Puller 2870386 Clutch Bushing Replacement Tool Kit PN 2871226 NOTE Bushings are installed at the factory using Loctite In order to remove bushings it will be necessary to apply heat evenly to the area around each bushing Clean all residual Loctite from Item Qty Part Description Part P 90 Drive Driven Clutch ie i Bushing Install Too
32. pane 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 Pull bushing removal tool and adapter from puller rod Remove bushing from tool and discard Drive Clutch Bushing Installation 1 10 Place main adapter Item 8 on puller Puller Tool A B Side A toward sheave Nut C Bushing Piston Pin Puller ETAT ETAT 8 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 NOTE 800 EFI Clutch Use Bushing Tool PA 47336 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 Cover Bushing Removal 1 Install main adapter Item 8 on puller Removal Tool AE f E S Adapter Reducer E Piston Pin Puller Main Adapter 8 Install adapter reducer Item 9 From outside of clutch cover insert removal tool Item 3 into cover bus
33. r adapter Item 10 onto puller 2 Install adapter Item 9 onto puller EBS Driven Clutch OuterBushing Installation Nut C Bushing Tool 2 Puller Adapter 10 P 3 Apply Loctite 609 evenly to bushing bore inside moveable sheave install assembly into sheave 6 Install left hand thread nut C 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 8 Remove nut C from puller rod and set aside 9 Remove installation tool and clutch sheave from puller 6 29 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Clutch Assembly 3 Line up the X on the moveable sheave with the X 1 2 NOTE Press only on the outer race of the bearing during installation to prevent damaging the bearing 6 30 on the stationary sheave or use the marks previously Install a new bearing onto the clutch shaft using an used Put the sheaves together arbor press Once bearing is fully seated install a new snap ring Align X s Bearing Install the shaft and bearing assembly into the outer sheave Press on outer race of bearing during installation 4 Install the roller A onto the roller pin B on both sides 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc C
34. shaft Do not attempt disassembly of the driven clutch from the outside snap ring The driven clutch must be disassembled from the helix side 2 It is important to mark the position of the shaft cam cover and sheave before disassembly or use the X s on the components for reference This will aid in reassembly and helps to maintain clutch balance after reassembly 3 Remove the four screws that secure the cam helix assembly using a T25 Torx driver FE gt y 4 Place the driven clutch into the Universal Clutch Compressor PU 50518 PU 50518 5 Press down on the top of the spider assembly pushing the spider onto the shaft Remove snap ring A and slowly release the assembly Press down on spider 9923499 2011 2012 RANGER 800 Service Manual O Copyright 2011 Polaris Sales Inc CLUTCHING 6 Remove the spider assembly and spring B 10 Press out the spring pins I in the inner sheave NOTE Spring is compression only and has no torsional wind 7 Remove the inside spider plate D and spider dampener E Inspect the spider dampener E for wear and replace if needed 12 Press the shaft and bearing out of the outer sheave using an arbor press 8 Remove the E clips F washers G and the clutch rollers H Inspect the rollers for wear replace if worn 9 Remove the clutch assembly from the holding tool 6 27 9923499 2011 2012 RANGER 800 Service
35. special tools and service procedures Driven Clutch Retaining Bolt 17 ft Ibs 23 Nm PVT Inner Cover Phillips Head Screws Sins AS 6 NN PVT Inner Cover Has Head Screws 12 ft lbs 16 Nm PVT Outer Cover Bolts 45 50 in lbs 5 5 6 Nm Drive Clutch Spider 200 ft lbs 271 Nm Drive Clutch Cover Plate 90 in lbs 10 Nm 6 2 The Polaris Variable Transmission PVT consists of three major assemblies 1 The Drive Clutch 2 The Driven Clutch 3 The Drive Belt The internal components of the drive clutch and driven clutch control engagement initial vehicle movement clutch upshift and backshift During vehicle development 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 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Drive Clutch Operation Drive clutches primarily sense engine RPM The two major components which control its shifting function are the shift weights and the coil spring Whenever engine RPM is increased centrifugal force is created causing the shift weights to push against rollers on the moveable sheave which is he
36. t has not turned in the sheave after tightening Bearing Inspection the spider during clutch assembly 1 Rotate the clutch bearing in both clockwise and 3 Remove cover bolts evenly in a cross pattern and counter clockwise directions remove cover plate Non EBS The non braking bearing should rotate 4 Inspect cover bushing A The outer cover bushing is both directions on the shaft with only a slight manufactured with a Teflon coating Wear is amount of drag determined by the amount of Teflon remaining on the bushing e EBS The one way bearing should rotate clockwise when viewed from cover plate side with only a slight amount of drag When rotated counter clockwise the one way bearing should lock to the shaft without slipping 2 Verify there is no binding or rough spots If problems are noted continue with disassembly Cover Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to bushing replacement in this chapter 6 15 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Drive Clutch Spring Inspection CAUTION 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 The drive clutch spring is one of the most critical components of the PVT system It is also one of the easiest
37. to hold it in place 5 Fit lip of inner cover seal A to engine Install seal retainer plate and tighten screws securely C y Seal outer edge to cover with RTV silicone sealant 6 Torque rear inner cover bolts B to specification 7 Install clutch alignment washer s on transmission input shaft we Alignment Washer s 10 Remove inner cover retaining bolts at rear of cover 11 Remove cover along with foam seal on back of cover or shaft Assembly 1 Inspect PVT inner cover to engine seal Replace if cracked or damaged Apply RTV Silicone Here 8 Clean splines inside driven clutch and on the y transmission input shaft 9 Apply alight 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 idee specification 2 Place a new foam seal on transmission input shaft 6 6 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING 13 Reinstall drive belt noting direction of rotation lfanew DRIVE BELT NON E BS belt is installed install so numbers can be easily read Belt Removal 14 Replace PVT outer clutch cover rubber gasket 1 Remove outer PVT cover as described in PVT 15 Reinstall PVT outer clutc
38. to sheave clearance be sure to reinstall the original 1 Inspect for any clearance between spider button to quantity and thickness of washers spacers beneath tower If clearance exceeds specification replace all the spider during assembly buttons and inspect surface of towers See Spider Removal procedure Spacer Washers Spider Button to Tower Clearance 000 005 Moveable Sheave Bushing Inspection 2 Inspect the Teflon coating on the moveable sheave 2 Inspect sheave surfaces Replace the entire clutch if bushing worn damaged or cracked Spider Removal 1 Install clutch in holding fixture PN 2871358 A and loosen the spider counterclockwise using Clutch Spider Removal Tool PN 2870341 Teflon 2870341 L Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing Refer to Bushing Service in this chapter 2871358 A Clutch Holding Fixture PN 2871358 A Spider Removal Tool PN 2870341 6 17 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING Roller Pin and Thrust Washer Inspection d Inspect all rollers bushings and roller pins by pulling a flat metal rod across the roller Turn roller with your finger If you notice resistance galling or flat spots replace rollers pins and thrust washers in sets of three Also
39. utlet duct hose and tighten the driven clutch retaining bolt to 17 ft Ibs 23 5 Nm Be hose clamps sure to rotate the driven clutch counterclockwise several times to ensure the belt is tight and riding at 13 Install the LH storage container and lower seat base the proper height 14 Sit in the driver s seat apply the brake and start the engine Place the gear selector in high range and test the vehicle for drive clutch drag or hard shifting while at idle speed If shifting remains difficult refer to CLUTCH CENTER DISTANCE to check positioning of the engine and transmission mounting CAUTION Do not leave the vehicle unattended DS SA 17 ft lbs Da 23 5 Nm ll 9 Inspect the belt to sheave clearance again If the belt rests evenly between the drive clutch stationary and moveable sheaves the offset is correct and the vehicle can be reassembled If the belt is still contacting either sheave repeat steps 6 9 until the correct offset is achieved 10 Inspect the outer clutch cover gasket Replace if damaged 11 Install the outer clutch cover and 8 screws Torque screws to specification e T Outer Clutch Cover Retaining Screws 45 50 in Ibs 5 5 Nm 6 13 9923499 2011 2012 RANGER 800 Service Manual Copyright 2011 Polaris Sales Inc CLUTCHING DRIVE CLUTCH SERVICE Exploded View Bushing Lock Spider 200 ft lbs Cover Z Sprin amp x 271
40. ve Clutch Puller 2870506 Drive Clutch Spider Removal and 2870341 Installation Tool Piston Pin Puller 2870386 Roller Pin Tool 2870910 Universal Clutch Compressor PU 50518 SPX Corp 1 800 328 6657 or http polaris spx com SPECIAL SUPPLIES PART NUMBER Loctite 609 N A RTV Silicone Sealer 8560054 TORQUE SPECIFICATIONS PVT System Fastener Torques ITEM TORQUE VALUE Drive Clutch Retaining Bolt 47 ft los 64 Nm HIGH ALTITUDE CLUTCH CHARTS All Models Except 2012 RANGER HD Shift Drive Driven Atitude Weight Spring Spring 0 1500 23 62 Black Bik Almd Meters 0 5000 5632337 7043594 7043167 Feet 1500 3700 23 58 B Black Blk Almd 5000 12000 1322911 7043594 7043167 2012 RANGER HD EBS P Shift Drive Driven Altitude Weight Spring Spring 0 1500 23 62 Black Red Meters 0 5000 5632337 7043594 3234452 Feet 1500 3700 23 58 B Black Red 5000 12000 1322911 7043594 3234452 PVT SYSTEM OVERVIEW General Operation WARNING All PVT maintenance or repairs should be performed by a certified Polaris Master Service Dealer MSD technician who has received the proper training and understands the procedures outlined in this manual Because of the critical nature and precision balance incorporated into the PVT components it is absolutely essential that no disassembly or repair be made without factory authorized
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