Service Manual

6.2
CLUTCHING
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 the Polaris vehicle,
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
Spider Nut Socket 2870338
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™ 680 2870584
RTV Silicone Sealer 8560054
ITEM
TORQUE VALUE
ft. lbs. (Nm)
Drive Clutch Retaining Bolt 40 ft. lbs. (54 Nm)
Driven Clutch Retaining Bolt 17 ft. lbs. (23 Nm)
PVT Inner Cover Bolts 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 Spider Lock Nut
(Plastic)
15 ft. lbs. (20.3 Nm)
Drive Clutch Cover Plate 90 in. lbs. (10 Nm)
WARNING
All PVT maintenance or repairs should be
performed only 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.