Clutch - Specifications; Clutch - Special Service Tools And Supplies; 1996 Productoin Specifications; 1996 Clutch Recommendations For Altitude - Polaris Magnum 2x4 Service Manual

Special Service Tools and Supplies
CLUTCHES
Specifications
Description Part Number
Drive Clutch Puller ......................... 2870506
Clutch Holding Fixture ...................... 2871358
Spider Removal Tool ........................ 2870341
Offset Alignment Tool ....................... 2870654
Driven Clutch Puller ........................ 2870913
Spider Pin Tool ............................. 2870910
Clutch Bushing Removal
&
Installation ........ 2871226
Piston Pin Puller (Also used with 2871226) .... 2870386
401 Loctite ................................ 2870769
RTV Silicone Sealer ........................ 2870661
Loctite/Chisel Gasket Remover .............. 2870601
1996 Production Specifications
OJ
PVT System Fastener Torques
Drive Clutch Retaining Bolt ... 40 ft. Ibs.
Driven Clutch Retaining Bolt .. 17 ft. Ibs.
PVT Inner Cover Bolts ....... 12 ft. Ibs.
Drive Clutch Spider ......... 200 ft. Ibs.
Drive Clutch Spider (Eng.brake) 185 ft. Ibs.
Drive Clutch Cover Plate .... 90 in. Ibs.
Machine Engine Model Operating RPM Drive Clutch Shift Wt. I.D. Driven Clutch Helix Angle
Model +/- 200 Spring Color and Gram Spring Position
Wt.
Trail Boss EC25PFE-08 6000 Blue/Green
16 40°
43 gr 2-2
Trail Blazer EC25PFE-09 5800 Blue/Green
G 40°
48 gr 2-2
300s EC28PFE-01 5600 Blue/Green G 44°-36°
48 gr
2-2
400s Except EC38PLE-04 5700 Blue/Green S-55 44°-36°
Scrambler/Sport 55 gr 2-2
Scrambler/
EC38PLE-05
5700 White S-55 40°
Sport 55 gr 2-2
425s EH42PLE-01 6000 Blue/Green 10MH
40°
(Magnums) 50.5 gr 2-2
500 EH50PLE-01 6000 Blue/Green 10MH 40°
Sportsman 50.5 gr
2-2
1996 Clutch Recommendations for Altitude*
OJ
Meters/Feet Trail Blazer ES Trail Boss 300 400 Except Scrambler/ 425/500
Scramb/Sport Sport 400L
Weight G (48 gr)
16
G 48 gr
S55 55 gr S55 - 55 gr
10MH 50 gr
0-900
Drive Spring Blue/Green Blue/Green Blue/Green Blue/Green White Blue/Green
0-3000'
Driven Spring/
(Red) 2-2
(Red) 2-2
(Red) 2-2
(Red) 2-2 (Red) 2-2 (Red) 2-2
Position
Weight G (48 gr) 16 G 48 gr S55 55 gr S55 - 55 gr 10MB
900-1800
Spring Blue/Green
Blue/Green
Blue/Green
Blue/Green White Blue/Green
3000-6000'
Driven Spring/ (Red) 2-1 (Red) 2-1 (Red) 2-2 or (Red) 2-2 or (Red) 2-2 or (Red) 2-2
Position 2-1 2-1 2-1
Weight 16 16 Mod F 45 gr S 53 gr S 53 gr 10MW
1800-2700
--
-,.,. "".,,'._- - -
Spring Blue/Green Blue/Green Blue/Green Blue/Green White Blue/Green
6000-9000'
Driven Spring/ (Red) 2-2 (Red) 2-2 (Red) 2-1 (Red) 2-1 (Red) 2-1 (Red) 2-1
Position
Weight 16 16 Mod F 45 gr S 53 gr S orC 10MR
2700-3700
Spring Blue/Green Blue/Green Blue/Green Blue/Green White Blue/Green
9000-12000'
Driven Spring/
(Red) 2-1 (Red) 2-1 (Red) 2-1 (Red) 2-1 (Red) 2-1 (Red) 2-1
Position
*
NOTE: Shift weights BH, RH, and WH (recommended for some 1998 models at high elevation)
supercede the 10MB, 10MR, and 10MW listed in the charts for some 1996 and 1997 models. Refer to page
6.3 for more information.
OJ
Refer to Page 6.31 for Engine Braking Clutch instructions, maintenance, and specifications.
Polaris Industries Inc.
6.1
5/98