General Information; Special Tools And Supplies; General Operation; Drive Clutch Operation - Polaris Sportsman XP 1000 S 2020 Service Manual

PVT SYSTEM

GENERAL INFORMATION

SPECIAL TOOLS AND SUPPLIES

PART NUMBER TOOL DESCRIPTION
Clutch Alignment Tool
PA-49011-A
Clutch Bushing Replacement Tool
2871025
Kit
Clutch Bushing Replacement Tool
2871226
Kit
2871710 Clutch Center Distance Tool
Clutch Holding Wrench
9314177-A
Drive Clutch Holding Fixture
2871358-B
Drive Clutch Reamer
PS-48587
Drive Clutch Spider Removal and
2870341
Installation Tool
Piston Pin Puller
2870386
Primary Clutch Puller
PU-52907
Roller Pin Tool
2870910-A
Universal Clutch Compressor
PU-50518-A
PART NUMBER SPECIAL SUPPLIES
N/A Loctite® 242 Blue
N/A Loctite® 609 Green
8560054
RTV Silicone Sealer
Bosch Automotive Service Solutions 1-800-345–2233
or www.polaris.service-solutions.com

GENERAL OPERATION

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.
The Polaris Variable Transmission (PVT) consists of
three major assemblies:
• The Drive Clutch
• The Driven Clutch
• The Drive Belt
6.2
WARNING
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.

DRIVEN CLUTCH OPERATION

Driven clutches primarily sense torque, opening and
closing according to the forces applied to it from the drive
belt and the transmission input shaft. If the torque
resistance at the transmission input shaft is greater than
the load from the drive belt, the drive belt is kept at the
outer diameter of the driven clutch sheaves.
As engine RPM and horsepower increase, the load from
the drive belt increases, resulting in the belt rotating up
toward the outer diameter of the drive clutch sheaves
and downward into the sheaves of the driven clutch. This
action, which increases the driven clutch speed, is called
upshifting.
Should the throttle setting remain the same and the
vehicle is subjected to a heavier load, the drive belt
rotates back up toward the outer diameter of the driven
clutch and downward into the sheaves of the drive clutch.
This action, which decreases the driven clutch speed, is
called backshifting.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.