Service Manual

7.2
CLUTCHING (PVT)
SPECIAL TOOLS AND SUPPLIES
TORQUE SPECIFICATIONS
PVT System Fastener Torques
PVT SYSTEM OVERVIEW
General Operation
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 the development of a Polaris ATV, the
PVT system is matched first to the engine power curve; then to
average riding conditions and the vehicle’s intended usage.
Therefore, modifications or variations of components at random
are never recommended. Proper clutch setup and careful
inspection of existing components must be the primary
objective when troubleshooting and tuning.
Drive Clutch Operation
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 held open by coil spring preload. When this force becomes
higher than the preload in the spring, the outer sheave moves
inward and contacts the drive belt. This motion pinches the
drive belt between the spinning sheaves and causes it to rotate,
which in turn rotates the driven clutch.
At lower RPM, the drive belt rotates low in the drive clutch
sheaves. As engine RPM increases, centrifugal force causes the
drive belt to be forced upward on drive clutch sheaves.
TOOL DESCRIPTION PART NUMBER
Drive Clutch Puller (Short) PA-48595
Clutch Holding Wrench 9314177
Clutch Holding Fixture 2871358-A
Drive Clutch Spider Removal and
Installation Tool
2870341
Roller Pin Tool 2870910
Clutch Bushing Replacement Tool Kit 2871226
Piston Pin Puller 2870386
Clutch Compression Tool 8700220
Clutch Bushing Replacement Tool Kit 2871025
SPECIAL SUPPLIES PART NUMBER
Loctite™ 609 N/A
RTV Silicone Sealer 8560054
ITEM TORQUE VALUE
Drive Clutch Spider 200 ft. lbs. (271 Nm)
Drive Clutch Retaining Bolt
47 ft. lbs. (64 Nm)
Left Hand Thread
Driven Clutch Retaining Bolt 13 ft. lbs. (18 Nm)
Drive Clutch Cover Bolts 100 in. lbs. (11 Nm)
Inner PVT Cover Screws 6-8 ft. lbs. (8-11 Nm)
Outer PVT Cover Screws 45-50 in. lbs. (5-5.6 Nm)
Drive Clutch Weight Pins 15-25 in. lbs. (2-3 Nm)
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 special tools
and service procedures.