Special Tools And Supplies; Torque Specifications; Pvt System Fastener Torques; Pvt System Overview - Polaris Ranger 500 2x4 2007 Service Manual

CLUTCHING

SPECIAL TOOLS AND SUPPLIES

TOOL DESCRIPTION
Clutch Puller
Clutch Holding Wrench
Clutch Holding Fixture
Spider Nut Socket
Drive Clutch Spider Removal and
Install Tool
Driven Clutch Puller
Roller Pin Tool
Clutch Bushing Replacement Tool
Kit
Piston Pin Puller
Clutch Compression Tool
Clutch Bushing Replacement Tool
Kit
Standard Clutch Alignment Tool
SPECIAL SUPPLIES
Loctite™ 680
RTV Silicone Sealer
Loctite Gasket Remover

TORQUE SPECIFICATIONS

PVT System Fastener Torques

ITEM
Drive Clutch Retaining Bolt
Driven Clutch Retaining Bolt
PVT Inner Cover Bolts
PVT Outer Cover Bolts
Drive Clutch Spider
Drive Clutch Spider Lock Nut
(Plastic)
Drive Clutch Cover Plate
6.2
PART NUMBER
2870506
9314177
2871358
2870338
2870341
2870913
2870910
2871226
2870386
8700220
2871025
2870654
PART NUMBER
2870584
2870661
2870601
TORQUE VALUE
ft. lbs. (Nm)
40 ft. lbs. (54 Nm)
17 ft. lbs. (23 Nm)
12 ft. lbs. (16 Nm)
45-50 in.lbs (5-5.6 Nm)
200 ft. lbs. (271 Nm)
15 ft. lbs. (20.3 Nm)
90 in. lbs. (10 Nm)

PVT SYSTEM OVERVIEW

General Operation

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.
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, the PVT system is
matched first to the engine power curve; then to average riding
conditions and the vehicle's intended usage.
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.
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.
WARNING
Therefore,
Whenever engine RPM is