Polaris 2004-2005 Sportsman 6x6, Service Manual

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CLUTCH
6.6
PVT ASSEMBLY
Seal this edge to cover on engine side
1. Inspect PVT inner cover-to engine seal. Replace
if cracked or damaged.
2. Place a new foam seal on transmission input
shaft.
3. Apply RTV silicone sealant to outside edge of
inner cover-to-engine seal, to ensure a water tight
fit between the seal and the cover. Surfaces must
be clean to ensure adhesion of silicone sealant.
4. Reinstall cover and tighten rear cover bolts just
enough to hold it in place.
Seal outer edge to cover
with RTV silicone sealant
A
B
C
5. Fit lip of inner cover seal (A) to engine. Install seal
retainer plate and tighten screws securely.
6. Torque rear inner cover bolts (B) to specification.
Inner Cover Bolt Torque (Rear):
12 ft. lbs. (16.6 Nm)
Driven Clutch Retaining Bolt Torque:
17 ft. lbs. (23.5 Nm)
Drive Clutch Retaining Bolt Torque:
40 ft. lbs. (55 Nm)
Offset
Spacer
Offset
Spacer
7. Install clutch offset spacers on transmission input
shaft.
8. Clean splines inside driven clutch and on the
transmission input shaft.
9. Apply a light film of grease to the splines on the
shaft.
10. Install the driven clutch, washer, lock washer, and
retaining bolt. Torque to specification.
11. Clean end of taper on crankshaft and the taper
bore inside drive clutch.
12. Install drive clutch and torque retaining bolt to
specification.
13. Reinstall drive belt noting direction of rotation. If a
new belt is installed, install so numbers can be
easily read.
PVT Cover Gasket
Toward outer cover
14. Replace PVT outer cover rubber gasket with the
narrow side out (C).
15. Reinstall PVT outer cover and secure with
screws.
16. Reinstall rear cab assembly and seat.