Polaris Sportsman 400, Service Manual

Page: 191 / 381

CLUTCH
6.7
PVT 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 on engine side.
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 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.
14. Replace PVT outer cover rubber gasket with the flat
side out (C).
15. Reinstall PVT outer cover and secure with screws.
16. Reinstall rear cab assembly and seat.
Seal this edge to cover on engine side
Seal outer edge to cover
with RTV silicone sealant
A
B
C
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
Spacers
Cover Gasket
Flat edge out
(Toward outer cover)