Drive Belt; Belt Deflection (Tension); Belt Removal - Polaris Ranger 500 2x4 2007 Service Manual

8. Clean splines inside driven clutch and on the transmission
input shaft.
9. Apply a light film of grease to the splines on the shaft.
10. Install the driven clutch, washer, lock washer, and retaining
bolt. Torque to specification.
11. Clean end of taper on crankshaft and the taper bore inside
drive clutch.
12. Install drive clutch and torque retaining bolt to
specification.
13. Reinstall drive belt noting direction of rotation. If a new belt
is installed, install so numbers can be easily read.
PVT Cover Gasket
14. Replace PVT outer cover rubber gasket with the narrow
side out (C).
15. Reinstall PVT outer cover and secure with screws Torque
to 45-50 in. lbs. (5-5.6 Nm).
16. Install the PVT cover outlet duct and tighten the clamps.
Inner Cover Bolt Torque (Rear):
12 ft. lbs. (16.6 Nm)
Outer Cover Bolt Torque:
45-50 in.lbs. (5-5.6 Nm)
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:
40 ft. lbs. (55 Nm)
Toward outer cover

DRIVE BELT

Belt Deflection (Tension)

Deflection Measurement
See Spec Below
Belt Deflection (Tension):
1 1/8" (2.9 cm) - 1 1/4" (3.2 cm)
Pinch the sheaves lightly together with clamp to prevent the belt
from being pushed into the driven sheave.
1. Place a straight edge on top of the belt between drive and
driven clutch.
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in photo.
If belt deflection is out of specification, adjust by removing or
adding shims between the driven clutch sheaves.
• Remove shims to decrease belt deflection
• Add shims to increase belt deflection
See "Driven Clutch Service".
At least one shim must remain between the inner and outer
sheave of the driven clutch. If proper belt deflection cannot be
obtained, measure drive belt width, length, and center distance
of drive and driven clutch, outlined in this section; all have an
effect on belt deflection.

Belt Removal

1. Remove outer PVT cover as described in PVT
Disassembly.
2. Mark the drive belt direction of rotation so that it can be
installed in the same direction.
CLUTCHING
Straight Edge
6.7
6