Polaris Outlaw 500 Service Manual page 68

3. Inspect or replace the crankshaft oil seal anytime the clutch
cover is removed for service. Install with the seal lip
pointed in toward the cover.
4. Remove the 6 screws holding the clutch pressure plate.
NOTE: The top clutch plate should rest in the
towers.
CAUTION
Assembly is under spring pressure. Wear safety
glasses during removal.
NOTE: Top Clutch Plate Aligns In Basket Towers
5. Remove and inspect the clutch pressure plate for wear,
cracks, etc. Check bearing for wear and smooth rotation.
Replace either component if found to be damaged or worn.
6. Remove the clutch plates and friction discs, keeping them
in order. Inspect the pressure plates for wear and warpage.
Inspect the friction plates for wear or damage to friction
material. If either are damaged or worn excessively, replace
the components as a set.
NOTE: Replace clutch pack if measured thickness
of friction material is less than .110" (2.8mm). The
top plate has slightly different friction pads and
should always be installed on top.
NOTE: Top Clutch Plate Aligns In Basket Towers
7. To remove the clutch basket, remove the plunger from the
center of the clutch and de-stake the nut to avoid damaging
the threads upon removal.
NOTE: Nut is staked on flat of transmission shaft
8. Installation: Reverse the procedures. Using a new nut,
torque the clutch basket retaining nut to 66-81 ft. lbs. (90-
110 Nm). Stake the nut at the flat on the transmission shaft.
Install the clutch plates in order of removal. Reinsert the
plunger into the shaft. Reinstall the cover, pressure plate
screws and springs. Torque the screws to 80–97 in. lbs.
(9–11 Nm).
ENGINE
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