Notice - Polaris
Contents
1. NOTE Keep track of the spacers that are on the jackshaft behind the driven clutch n U amp 6 Remove the intake horn and the brace from the chassis 11 Remove the exhaust manifold and gaskets 7 Remove the air box 8 Remove the exhaust system TERRAIN DOMINATION 9923892 2013 600 IQ Racer Service Manual gt POLARIS 2012 Polaris Sales Inc 5 14 12 Remove the fastener that holds the torque stop to the engine plate 13 Disconnect the spark plugs 14 Drain all coolant from the engine 15 Remove the lower center front cooling hose 16 Remove the hose from the top of the thermostat 17 Disconnect the impulse line from the crankcase 18 Remove the recoil handle and secure the recoil rope 19 Disconnect the EV solenoid water pump sensor regulator rectifier and stator connections 20 Remove the PTO EV assembly from the engine 21 Remove the front motor mount fasteners and washers 22 Remove the rear motor mount fasteners TERRAIN DOMINATION POLARIS 9923892 2013 600 IQ Racer Service Manual 2012 Polaris Sales Inc Engine and Cooling Systems 23 Remove the engine from the clutch side of the chassis Installation The following instructions is for an engine that is assembled with the engine mounting plates attached and the spark plugs and PTO EV assembly removed 1 From the clutch side place the engine into the ch2. ey T Drive Clutch Torque 50 ft lbs 69Nm 19 20 Place the driven clutch spacers on to the jackshaft Place the driven clutch on to the jackshaft and torque to specification Driven Clutch Torque 12 ft Ibs 17Nm 21 22 23 24 25 26 Verify clutch alignment Re install the drive belt Replace the belt cover Replace the side panels Replace coolant and bleed the cooling system After test running re torque the drive clutch bolt TERRAIN DOMINATION 9923892 2013 600 IQ Racer Service Manual 2012 Polaris Sales Inc eC POLRHRIS Engine and Cooling Systems ENGINE COMPONENT ASSEMBLIES IQ Racer Engine Mounting LOCK NUT A amp WASHER Sy RUBBER MOUNT p SPACER YZ LH ENGINE STRAP Lu s Qs MOUNT RUBBER MOUNT L 2 Yi B ey T A 28 ft lbs 38 Nm B 30 ft lbs 41 Nm Apply Loctite 242 TERRAIN DOMINATION 9923892 2013 600 IQ Racer Service Manual POLARIS A ige Manu 2012 Polaris Sales Inc 5 17 PVT System PVT SYSTEM ADJUSTMENTS Clutch Alignment Offset The engine is mounted in the bulkhead so the drive and driven clutches self align under high torque loads Offset is controlled by the number of washers installed on the jackshaft behind the driven clutch 1 Remove drive belt Push the driven clutch towards the bulkhead 2 Install the alignment tool into th
3. NOTICE Before running this machine a Service Needs to be performed Polaris has found a issue with the vendor supplied Motor Mount Straps being machined incorrectly causing engine placement to be incorrect Due to this issue you will need to replace both Motor Mount Straps with the supplied Motor Mount Straps included with your machine BEFORE RUNNING THE MACHINE Failure to make this change will cause Drive Train issue s and or Failures Please use the supplied information for proper installation and Clutch alignment procedures Also the choke cable free play needs to be checked Some sleds may have to little of free play causing the choke cable lever to break As always if you have any question call the Polaris Race Department 715 355 5157 and check the website for our Race Tips We are sorry for any inconvenience this may have caused but this was the best way to release the Race Sled for the upcoming race season in a timely manner Thank you and Good Luck This Race Season Engine and Cooling Systems ENGINE REMOVAL AND NOTE Grey colored springs are located on the INSTALLATION header pipe and should be replaced in the same area Removal 9 Separate the carburetors from the intake boots and secure it out of the way 1 Remove the hood and side panels 2 Disconnect the exhaust pipe sensor and remove the exhaust system 3 Turn the fuel valve to OFF 4 Remove the drive belt 5 Remove the drive and driven clutches
4. 0 060 PUSH CLUTCH HH I T EIEE TERRAIN DOMINATION 9923892 2013 600 IQ Racer Service Manual gt POLARIS 2012 Polaris Sales Inc
5. assis and onto the motor mounts 2 Apply Loctite 242 to the threads of each base fastener on the PTO EV and torque to specification EV Base 12 ft lbs 16Nm 3 Place the washers and nuts on to the front and rear motor mounts 5 15 Engine and Cooling Systems 4 Torque the motor mounts to specification ey T Motor Mount Torque 28 ft lbs 38Nm 5 Connect the electrical items 6 Connect the impulse line to the crankcase 7 Route the recoil rope to the correct position 8 Replace the hose to the thermostat housing 9 Replace the lower center front cooling hose 10 Connect he spark plug leads 11 Replace the front torque arm to the engine plate and route the harness wires in a secure place 12 Replace the exhaust manifold and gaskets Torque the mounting fasteners to specification ey T Manifold Fastener Torque 22 ft lbs 30 Nm 13 Replace the rear torque stop plate and torque the fasteners to specification e T Rear Torque Stop Plate Torque 28 ft Ibs 38Nm 14 Adjust the torque stop so that it is touching but not forcing on the engine 5 16 15 16 17 18 Place the carburetor back onto the intake boots and tighten the hose clamps to secure the carburetors Place the air box into the chassis Place the air intake horn onto the airbox and secure it to the chassis Replace the drive clutch and torque to specification
6. e drive clutch and on top of the driven clutch stationary housing 3 Verify the tool is seated in the drive clutch and the driven clutch is pushed tight against the jackshaft bearing washers TOOL PART APPLICATION NUMBER PS 47477 Light Weight LW Team Driven P2 4 The optimum setup is when the front and rear of the tool touch the driven clutch No gap should be present in the front and the rear clearance should not exceed 060 1 5 mm NOTE If the front of the alignment bar does not touch the driven sheave the maximum clearance cannot exceed 025 0 6 mm Offset Float Adjustment 1 Determine direction driven clutch needs to be adjusted 2 Remove driven clutch retaining bolt and remove driven clutch 3 With one 16 GA bushing installed add or remove offset washers from behind the driven clutch to set the proper offset 4 After adjusting the offset add or remove shim washers from behind the driven clutch bolt and washer to provide a 060 1 5mm driven clutch float on the jackshaft 6 12 Driven Clutch Offset Shim Washers Offset Washers 16 Gauge Bushing 7556509 QTY 1 023 7555917 AR 120 7555864 AR Float Washers 047 7555957 AR 063 7555734 AR AR As Required Always verify the driven clutch floats on the jackshaft CAUTION The jackshaft bearing will fail from side loading if the driven clutch is not allowed to float
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