Clutch Puller - Polaris 2005 SPORTSMAN 500 Servise Manual

CLUTCHING
SPECIAL SERVICE 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
EBS Clutch
Alignment Tool
EBS Bushing
Replacement Kit
Clutch
Compression Tool
Clutch Bushing
Replacement Tool
Kit
SPECIAL SUPPLIES
Loctitet 680 . . . . . . . . . . . . . . . . . . . .
RTV Silicone Sealer . . . . . . . . . . . . .
Loctite Gasket Remover
PVT SYSTEM FASTENER
TORQUES
Drive Clutch Retaining Bolt
Driven Clutch Retaining Bolt
PVT Inner Cover Bolts . . . . . . .
Drive Clutch Spider EBS Clutch
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Clutch Spider Lock Nut (Plastic)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Clutch Cover Plate
6.2
PART NUMBER
2870506
9314177
2871358
2870338
2870341
2870913
2870910
2871226
2870386
2872292
2201379
8700220
2871025
PART NUMBER
2870584
2870661
. . . . . . . . . . 2870601
. . . 40 ft. lbs. (54 Nm)
. . 17 ft. lbs. (23 Nm)
12 ft. lbs. (16 Nm)
. . . . . . 200 ft. lbs.
(271 Nm)
. 15 ft. lbs.
(20.3 Nm)
. . . . . 90 in. lbs. (10 Nm)
PVT OPERATION OVERVIEW
WARNING
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; and 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.
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.
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.
Therefore,
As engine RPM increases,