Polaris 2012 Sportsman Forest 500 International, Service Manual

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6.8
CLUTCHING
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Assembly
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.
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.
7. Install clutch alignment washer(s) 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 the NEW 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.
14. Replace PVT outer clutch cover rubber gasket.
15. Reinstall PVT outer clutch cover and secure with
screws. Torque to specification.
Apply RTV Silicone Here
B
C
A
Seal outer edge to cover
with RTV silicone sealant
Alignment Washer(s)