Special Tools And Supplies; Torque Specifications; Pvt System Overview; General Operation - Polaris 2009 Sportsman XP 850 Service Manual

CLUTCHING (PVT)

SPECIAL TOOLS AND SUPPLIES

TOOL DESCRIPTION
Drive Clutch Puller (Short)
Clutch Holding Wrench
Clutch Holding Fixture
Drive Clutch Spider Removal and
Installation Tool
Roller Pin Tool
Clutch Bushing Replacement Tool Kit
Piston Pin Puller
Clutch Compression Tool
Clutch Bushing Replacement Tool Kit
SPECIAL SUPPLIES
Loctite™ 609
RTV Silicone Sealer

TORQUE SPECIFICATIONS

PVT System Fastener Torques
ITEM
Drive Clutch Spider
Drive Clutch Retaining Bolt
Driven Clutch Retaining Bolt
Drive Clutch Cover Bolts
Inner PVT Cover Screws
Outer PVT Cover Screws
Drive Clutch Weight Pins
7.2
PART NUMBER
PA-48595
9314177
2871358-A
2870341
2870910
2871226
2870386
8700220
2871025
PART NUMBER
N/A
8560054
TORQUE VALUE
200 ft. lbs. (271 Nm)
47 ft. lbs. (64 Nm)
Left Hand Thread
13 ft. lbs. (18 Nm)
100 in. lbs. (11 Nm)
6-8 ft. lbs. (8-11 Nm)
45-50 in. lbs. (5-5.6 Nm)
15-25 in. lbs. (2-3 Nm)

PVT SYSTEM OVERVIEW

General Operation

WARNING
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:
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 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.
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.
Proper clutch setup and careful
Whenever engine RPM is