Polaris Sportsman XP 1000 S 2021 - Drive Clutch Assembly

6
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
6.21
8. Remove bushing and removal tool from puller.
Discard bushing.
COVER BUSHING INSTALLATION
1. Apply Loctite® 648 evenly to bushing bore in cover.
2. Working from inside of cover, insert new bushing and
bushing installation tool into center of clutch cover.
3. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise.
4. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed.
5. Turn clutch cover counterclockwise on puller rod until
bushing is seated.
6. Remove nut from puller rod. Take installation tool and
clutch cover off rod.
DRIVE CLUTCH ASSEMBLY
IMPORTANT
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the following sequence.
Be sure the marks that were made during disassembly
are aligned during each phase of assembly.
1. Install the shift weights, bolts and nuts onto the
movable sheave. Torque nuts to specification.
TORQUE
Shift Weight Nuts
20 in-lbs (2 N·m)
2. Install the one way bearing
q
, two washers
w
, and
spacer
r
onto the stationary sheave
e
.
3. Install movable sheave onto stationary sheave shaft.
Be sure the movable sheave slides freely on the
spacer.
4. Apply 0.4 mL of Loctite® 620 and 0.4 mL of Loctite®
7088 Primer in 90º apart in vertical stripes to the shaft
threads.
5. Install the spider assembly onto the shaft threads. Be
sure all of the alignment marks
u
are in alignment.
ITEM DESCRIPTION
t
Moveable Sheave
y
Spider
u
Alignment Marks
PVT SYSTEM