Drive Clutch Installation - Polaris 2007 Two Stroke Service Manual

CLUTCHING

Drive Clutch Installation

NOTE: Always clean the clutch taper before re-installing clutch on engine.
1. Place a clutch taper reamer (PN 2870576) in a vise (A) and lubricate the cutting edges with cutting oil. Clean the clutch taper
by manually rotating the clutch clockwise on the reamer one or two revolutions. Only use the weight of the clutch and do not
push down on the clutch while turning. This will clean up any galling or scoring of the bore taper.
2. Check crankshaft taper for galling or scoring. If necessary clean the taper evenly with 200 grit emery cloth (B).
3. The clutch taper and the crankshaft taper should be clean and dry. Do not use harsh cleaners which may cause clutch taper to
corrode, or damage the crank seal.
4. Clean clutch taper with lacquer thinner or isopropyl alcohol (C).
5. Slide clutch onto crankshaft taper (D).
6. Install the retaining bolt with all spacers and washers or o-rings (E) that were on the bolt when it was removed.
7. Hold the clutch with the holding wrench (F) PN 931417-A. Re-check torque after first operation or test ride.
8. Torque retaining bolt to specification.
9. Run engine then re-torque the retaining bolt to specification.
6.20
Drive Clutch Bolt Torque
ENGINE
Fuji
Liberty 440/500/600/
700 carbureted
Liberty 600/700 CFI
CAUTION
Re-torque the drive clutch bolt after running the engine
for several minutes.
BOLT TORQUE
40-45 ft-lb (55-
7/16-20
62N-m)
14mm 50 ft-lb (68N-m)
14mm 80 ft-lb (108N-m)