Clutching - the Polaris International Extranet
Contents
1. CLUTCHING NOTE we uno 02 hours salector range engine to idi for five minutes 1 break nthe drive hub bearing caution 69 CLUTCHING DRIVE BELT Belt installation NOTE Be sure position belt in the same position when removed or so number is easy read CLUTCHING DRIVE CLUTCH SERVICE Spring Specifications ees caution evar Sa ED RRS compression rale The may rau m complet facing o e cols and es oping ind ure Ee Primary Clutch Springs 611 CLUTCHING Shift Weights jenen enge tr thang 2009 Shift Weights M i gt 8 5 A Y mesas Passer 2010 Shift Weights 2009 Non Braking Exploded View 828 CLUTCHING Song Na NE CON Y m N i y oe SALE SK xc IA Yaa 6 13 CLUTCHING 2010 Non Braking Exploded View All Models wem X 8 Spacer 26 SS N M A _ IS RT a 4 iL SS Clutch Disassembly CLUTCHING spider during assembly sure to note the number hd thickness of these washers POTETE Seng Seca or quia ine2. Ow PanDesenpuon CON 1 EE 1 p NOTE Bushings are Installed at the factory using ings It vill be bushing bore prior to Installing new bushing Clutch Bushing Removal 2 tal em CLUTCHING Clutch Bushing Installation 6 25 CLUTCHING Clutch Assembly CLUTCHING 8 6 28 A252 475 588 Nm CLUTCHING Exploded View Early Bulld 2009 RZR All 2009 RZR 8 6 29 CLUTCHING DRIVEN CLUTCH SERVICE LATE BUILD 2009 RZR ALL 2010 MODELS Exploded Compresion Spring Spacer caution Cay reno ig Clutch Disassembly Inspection o prevent serious personal jun Use when removing Shap ng pressures loaded by the compression sping NOTE Spring is compression only and has no 6 30 CLUTCHING CLUTCHING CLUTCHING TROUBLESHOOTING ER II ete RTS far bone pee P 6 33 CLUTCHING Troubleshooting Continued 6 34
3. 2 tl pe rede Cover Bushing Installation mal u on a phe puller rl o ply mo Clutch Assembly Important thatthe same number and washers are reinstalled beneath the Spider during assembly The Teflon bushings are CLUTCHING caution 200 be 271 Do ET oT or grease Toe DUSTING seh pin of fe Spacer washers om pier aligns Xo the hl were made caution TE SU SPST WTS TE TOR eld ha recs pide Any nisalrment water cun nvering he ct we italy inten the sider wi help positon he washers aver Seren SD bs 104 Nm 6 21 CLUTCHING DRIVEN CLUTCH SERVICE EARLY BUILD 2009 RZR ALL 2009 RZR 5 Clutch Disassembly Aer pneu ames on epider NOTE Spring is compression only and has no torsional wind CLUTCHING CLUTCHING Bushing Service IMPORTANT Special Tools Required Bushing EBS Clutch Bushing Tool Kit 2201379 Tem Oy Tarbescpon Parr Additional Special Tools ay Fan Desenten LL EE Inspect sheave Surface 6 24 clutch Bushing Replacement Tool PN 287126
4. Inspection Moveable Sheave Bushing Inspection Replace the cover bushing more brass han Teflon is visible on the bushing Refer to bushing replacement in this chapter CLUTCHING Bushing Service IMPORTANT Special Tools Required EBS Clutch Bushing Tool Kit 2201379 Tem CS ELLES Parr D emam Additonal Special Tools ay LUE LL 1 EE 257125 Moveable Sheave gt Bushing Removal caution serous bums wear goves Guin the movit process Clutch Busing Replacement Tool 2871226 Wem ON Deserpion FT i ae Aer ELL p NOTE Bushings are installed at the factory using Loctite 608 In order to remove bushings Il wll be each bushing Clean all residual mom 7 bushing bore prior t Insaling new bushing Main Pur Aptos EN pale soper in re D et ale UCM px m Piston Pin 12 6 19 CLUTCHING NOTE Use Bushing Too 42536 Stat Cote of pullerend and and tight Tm Drive Clutch Bushing instalation 1 Pic min ater em 8 ple Main Adapt 2 Apply Locis evenly to Bing bore inside ta et on ple band gen Tum are to ply ol nso seed 6 20 Cover Bushing Removal T Reducer 0
5. Moveable Sheave Bushing inspection Spider Removal pun Moveable Sheave Bushing Inspection Replace the cover bushing if more brass than Teflon is visible on the bushing CEE Y Refer to bushing replacement Diese 6 15 CLUTCHING Roller Pin and Thrust Washer Inspection 7 Ai oi ler pie changed the d mer pin Shift Weight Inspection NOTE The rubber side ofthe button is posiioned Howard the soli roller 6 16 Button To Tower Clearance Inspection Inet o any hace betwee sper ton to tomer ence ete repisa boon and pec te Button to Tower Clearance 000 001 1 maces he emire clue if worm SSO un Neve pots wit used om other catch assembly CLUTCHING pivot ots for wear gli I wogh ol NOTE A damaged shit weight Bearing Inspection Soy sig anc ot dog Wiz anni Clutch Inspection NOTE Remove cover spring and spider following Instructions for drive clutch removal then proceed 2 Moe om esi Service Limit 025 54 mm 2 Lin being Cad thrust water hal Replace a not mage wee mtd era oat re 6 17 CLUTCHING In mm Standard 00 7 mm Serie Limit 025 6 18 Moveable Sheave Bushing
6. CLUTCHING CHAPTER 6 CLUTCHING SPECIAL TOOLS AND SUPPLIES 62 TORQUE SPECIFICATIONS 62 PVT SYSTEM OVERVIEW 62 PUT BREAKIN DRIVE BELT CLUTCHES PVT SYSTEM SERVICE DRIVE BELT PPT BREAKIN ORME BELT CLUTCHES DRIVE CLUTCH SERVICE en oo cas ExPLODED view RR n DRIVEN CLUTCH SERVICE EARLY BUILD 2009 RZR ALL 2009 RZR 5 62 XLODED view EARLY BLL 2605 AL 200 RR j DRIVEN CLUTCH SERVICE LATE BUILD 2009 RZR ALL 2010 MODELS 630 TROUBLESHOOTING A A A 84 CLUTCHING SPECIAL TOOLS AND SUPPLIES PVT SYSTEM OVERVIEW TOOL DESCRIPTION PARTWUNEER Gun Holding Wrench snam Catch ong Fire Tia Bunting Cus Compression Lr lah Busting Replacement 2973025 SPECIAL SUPPLIES _ PART NUMBER TORQUE SPECIFICATIONS PVT System Fastener Torques Fa TORQUE VALUE Dive CN Retaining Bar 40s EL A PVT Oner Cover Bos TE Dave Guen Nj ive Cu Cover Pate ba 62 General Operation wanna PU mania shoud DE ceret Poe Master Service USD who road prope aig and S he procedures s mu and service procedures Drive Clutch Operation CLUTCHING Driven Clutch Operation to the forc ap rm ee belt a
7. ds Gite seas shou e inspected far damage peste leaking occus TIC ORDRE TOUTS FTP DIE Tore TENTE TI ua pump may cause symptoms Seno mafuncten Law Heavy paling basi operational spacds ess T PH rng non rough eran swamps mountains ect or iow ground spe Ion un epee TF spends above Poor eng performance GENERAL RANGE OPERATION Operating in Low Gear IMPORTANT Using High gear for heavy loads hl terrain rn wet muddy conditions wll inerease the chance of drive belt burning 64 CLUTCHING PVT SYSTEM SERVICE PVT Covers and Ducting Components 878 878 5 RZR INT L AN PVT Covers and Ducting Components RZR 4 ES a CLUTCHING PVT Disassembly Drive Clutch Puller PA 18595 Drive Clutch Holder 9314177 CLUTCHING PVT Assembly CLUTCHING Inner Cover Bolt Torque Rear 120 Ibs 16 6 Nm Outer Cover Bolt Torque 45 50 in bs 5 56 Nm Driven Clutch Retaining Bolt Torque TM Ibs 23 5 Nm Drive Clutch Retaining Bolt Torque 40 f Ibs 54 Nm 68 Clutch Offset Procedure removed Senous uty may eu ich reining hl v 17 ft 235 Nm ur Seite lp nding proper ch eng bol o 1 RS Nm Be sure fo Soule
8. pd be ven lth ped called rsen ich ped called basing PVT Break In Dri t Clutches Maintenance Inspection 63 CLUTCHING Overheating Diagnosis Law during loading ofthe vehicle ta prevent bel bury rer unen in ange aldo UT DOTS SI WT IT an a poston of the ence to prevent bat at ow RPH or ow EL pend oT ase ow The us al Las MEN PERSO 37 eder operating temperatures and longer componen e TRE GIGS TEA ANNE vote to approx 18 tte im shat bursts 10 7 mes The bel wi oocome mote fente and prevent al burg Insumeiontergne when posed ow arden sow anc en Gne Tor ECS engagent CPS TION RP Loy oy round speed LL Tow ony SF Tis TESTO TE SS TST suck in mud or anon olcaton to engage cute WARNING Excessive tate may cause los SF Tis VOTES TO ESO TS TST OTIS Loplcaton to engage cn WARNING Excessive tate moy cause los over large objects asa positon an vehicle overt TE UTS TS TOUS VST TE TIT FT se sopage tom water or now detotut tte Repeat several ines as required During e procedure io the system he shouts notte held att fl posto more Pan 10 secon
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