CHAPTER 6 CLUTCHES

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Service Tools, All drive clutch maintenance disassembly and assembly must be performed only by an authorized Polaris dealer. who has attended current model Dealer Service Seminars has received a certificate of completion and displays. the Polaris Servicing Dealer decal, Because of the critical nature and precision balance incorporated into the drive clutch it is absolutely essential that. no attempt at clutch disassembly and or repair be made without factory authorized tools and service procedures. Essential Drive Clutch Tools, Refer to the Service Tool Catalog PN 9914681 for photos and descriptions of all tools. Description Part Number, Offset Alignment Tool 21 32 1 7 em P 90 Clutches 2870914. Offset Alignment Tool 5 8 1 6 em P 85 Clutches 2870426. T Handle Drive Clutch Puller Large Shaft 10 2870506. Drive Clutch Puller 14mm Small Shaft ID 2871757,Strap Wrench 2870336.
Replacement Strap for 2870336 2870389,Spider Spanner Nut Driver Jam Nut 2870338. Spider Removal Installation Tool 2870341,Holding Fixture 2871358. Holding Fixture Tab 5130518,Tapered Reamer 2870576. Spider Button Tool 2870985,Clutch Bushing Rebuild Tool Kit P 85 P90 2871025. P 85 Drive Clutch Compression Tool 2870984,Driven Clutch Puller P 90 2871056.
Torque Wrench 250ft lb 0 0 Commercially Available, Torque Wrench 0 600 in lb 0 0 0 Commercially Available. Clutch Compression Tool 0 0 0 0 0 0 0 8700220,Polaris Industries Inc 6 1 9 97. Clutch Torque Values,Bolt Size Area Where Used Torque Minimum Maximum. 7 16 Drive Clutch Retaining Bolt 40 45 ft lbs 5 52 6 21 kgm. 14mm Drive Clutch Retaining Bolt 50 ft lbs 6 9 kgm. 1 4 Drive Clutch Cover Bolts 90 in lbs 1 03 kgm,1 0 24 Drive Clutch Weight Pin 30 in lbs 34 kgm. 1 1 4 Drive Clutch Spider 200 ft lbs 29 60 kgm, 1 1 4 Drive Clutch Spider Jam Nut 235 ft lbs 32 43 kgm.
5 16 Driven Clutc h Retaining Bolt 15 ft lbs 2 07 kgm. 8 32 Driven Button Screw 20 in lbs 23 kgm, 1 4 Driven Adjust Plate Screw 10 ft lbs 1 38 kgm see decal. 9 97 6 2 Polaris Industries Inc,Specifications, 1996 Clutch Specifications 0 3000 Feet 0 900 Meters. Machine Engine Operating Production Spnng Shift Wt Bore Clutch Driven Chaincase. Model Model RPM ClUtch Color I D Gram Taper Center Helix Gearing. 200 Part No Wire Dia Distance Angle,Dia 100 Location. Indy Lite GT ECa4 2PM02 7000 1a21601 Silver 10 1 160 11 030 a6 5 4 16 a9. Indy Lite Deluxe 1321602 Gold B 2, Indy Sport EC44 3PM01 6800 1321594 Brown 10 1 160 12 00 a6 5 16 35. Indy Sport Touring 200 B 2 16 39,Indy TranSport 15 39.
Indy Super Sport EC50PM06 7000 1321619 Red 10AL 1 160 12 00 36 5 17 a5. W hile Bushed B 2, Indy Trail EC50PM04 7000 1321659 Red 10AL 1 190 12 00 as 21 39. White Bushed 2, Indy Trail Touring EC50PME04 7000 1321660 Red 10AL 1 190 12 00 as 20 39. White Bushed 2, Indy WideTrak GT EC50PM03 6600 1321661 Brown 10 1 190 12 00 36 19 41. 200 Bushed 112, Indy WideTrak LX EC50PLE12 7000 1321644 Brown 10 1 190 12 00 36 19 41. 200 Bushed 2, Indy 440 LC EC45PL06 8000 1321580 Gold 10MB 1 190 12 00 34 2 1 39.
207 Bushed 2, Indy 440 XCR EC45PL07 8250 1321648 Blue 10MB 1 190 12 00 34 21 a9. 207 Bushed 2, Indy 440 XCR SP EC45PL08 8250 1a2164a Blue 10M 1 190 12 00 R 8 21 39. 207 Bushed 2, Indy 500 EC50PL 11 7750 1321663 Gold 10M 1 190 12 00 as 21 a9. Indy 500 SKS 207 Bushed 2 20 39, Indy 500 RMK EC50PL11 7750 1321655 Gold 10M 1 190 12 00 36 20 39. 207 Bushed 2, Indy Classic EC50PLE11 7750 1a21666 Gold 10M 1 190 12 00 as 21 39.
207 Bushed 2, Indy Classic Touring EC50PL 14 7750 1321606 Gold 10 MB 1 190 12 00 34 20 39. 207 Bushed 2, Indy 500 EFI EC50PL 13 8000 1321663 Gold 10 M 1 190 12 00 36 2 1 39. Indy 500 EFI SKS 207 Bushed 2 20 39, Indy 500 EFI RMK EC50PL13 8000 1321655 Gold 10M 1 190 12 00 36 20 39. 207 Bushed 2, Indy XLT XLT SKS EC58PL03 8000 1321665 Gol d 10M 1 177 12 00 34 21 39. 207 Bushed 2, Indy XLT RMK EC58PL07 8000 1321656 Gold 10M 1 177 12 00 34 18 39.
207 Bushed 2, Indy XLT Touring EC58 PLE05 8250 1321664 Gold 10M 1 174 12 00 34 20 39. 207 Bushed 2, Indy XLT SP EC58PL02 8500 1321678 Blue 10MB 1 177 12 00 34 21 39. 600 XCR 207 Bushed 2, Indy 600 XCR SP EC59 PL01 8500 1321650 Blue 10 AL 1 177 12 00 R 1 2 1 35. 207 Bushed 2, Indy RXL EC65PL05 8000 1321650 Blue 10 AL 1 177 12 00 as 21 35. 207 Bushed 2, Indy Ultra SP SKS EC68PL01 8200 1321682 Silver 10 1 177 12 00 as 21 35.
Gold Bushed 2, Indy Ultra RMK EC68PL04 8200 1321678 Silver 10 1 177 12 00 36 20 35. Gold Bushed 2, Indy Storm EC80PL05 8250 1a2165 1 Blue 10 60 1 177 12 50 R a 23 37. Indy Storm SKS 207 Bushed 2 20 35, Indy Storm AMK ECBOPL04 8250 1321658 Blue 10 60 1 177 12 50 A 3 20 35. 207 Bushed 2, NOTE RMK production setup is 6000 9000 feet Refer to page 6 4 for 1996 RMK production setup. Polaris Industries Inc 6 3 9 97,High Elevation Specifications.
1996 HIGH ELEVATION RECOMMENDATIONS, 3000 Ft to 6000 Ft 6000 Ft to 9000 Ft 9000 Ft to 12000 Ft. Mach1ne Chain Chain Chain, Model Shift Clutch Driven case Shift Clutch Driven case Shift Clulch Driven case. Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix Gearing. Indy Lite 10MB Gold 36 5 16 39 10M Gold 36 5 16 39 10M White or Blue 36 s 16 39. GT Deluxe B 2 White IIB 2 10M Red Gold B 2, Indy Sport 10 Red White 36 5 16 35 10 Gold 36 5 16 35 10 or Blue 36 5 16 35. IIB 2 Bushed B 2 10M Blue Gold IIB 2, Indy Sport 10 Red White 36 5 16 39 10M Gold 36 5 16 39 10 or Blue 36 5 16 39. Touring B 2 Bushed IIB 2 10M Blue Gold B 2, Indy 10 Red White 36 5 15 39 10 Gold 36 5 15 39 10or Blue 36 5 15 39.
TranSport IIB 2 B 2 10M Blue Gold B 2, Indy Super 10 Red White 36 5 17 35 10AL Gold 36 5 17 35 10MB Bushed Red White 36 5 17 35. Sport Bushed IIB 2 Bushed B 2 10 Bushed Gold B 2, Indy Trail 10AL Gold 36 2 1 39 10 Gold 36 21 39 10MB Gold sa 21 39. Touring Bushed Red White 2 20 39 Bushed Red White 112 20 39 Bushed Red White 2 20 39. In Wide 10 Red White 36 19 41 10M Red White 36 19 41 lOMB Red Wh1te 36 19 41. Tr GT Bushed 2 Bushed 2 Bushed 112, Indy wide 10 Red White 36 19 41 10MB RedtWhile 36 19 41 10MW Bushed Red White 36 19 41. Trak LX Bushed 112 Bushed 112 112, Indy 440 tOMW Blue 34 2 1 39 10MR Blue 34 21 39 10MR Blue 34 21 39. LC Bushed 2 Bushed 2 Bushed 112, Indy 440 10MW Blue 34 2 1 39 10MW Blue 34 21 39 10MR Blue 34 21 39.
XCR Bushed 112 Bushed 2 Bushed 2, Indy 440 10MB Blue R 8 2 1 39 tOMW Blue R 8 21 39 10MR Blue R 8 21 39. XCRSP Bushed Bushed Bushed, Indy 500 10MB Gold 36 21 39 tOMW Blue 36 21 39 tOMR Blue 36 21 39. Bushed 2 Bushed 2 Bushed 2, Indy 500 10MB Gold 35 20 39 tOMW Blue s6 20 39 tOMR Blue 36 20 39. SKS bushed 2 Bushed 2 Bushed 2, Indy Clas 10MB Blue 34 20 39 10MW Blue 34 20 39 10MR Blue 34 20 39. sic Touring Bushed 2 Bushed 112 Bushed 2, Indy tOMB Gold 36 21 39 tOMW Blue 35 21 39 10MR Blue 36 21 39.
Class1c Bushed 2 Bushed 2 Bushed 2, Indy 500 tOMB Gold 36 20 39 10MW Blue 35 20 39 10MR Blue 36 20 39. RMK Bushed 2 bushed 2 Bushed 2, Indy 500 tOMB Gold 36 2 1 39 10MW Blue 36 21 39 10MR Blue 36 21 39. EFI Bushed 2 bushed 112 Bushed 2, Indy 500 10MB Gold 36 20 39 10MW Blue 36 20 39 10M A Blue 36 20 39. EFI SKS Bushed 2 bushed 2 Bushed 112, Indy 500 10MB Gold 36 20 39 tOMW Blue 36 20 39 tOMR Blue 36 20 39. EFI RMK Bushed 112 Bushed 2 Bushed 112, Indy XLT lOMB Gold 34 21 39 t OMW Blue 34 21 39 tOM A Blue 34 21 39.
Bushed 2 Bushed 2 Bushed 2, Indy XLT 10MB Gold 34 20 39 10MW Blue 34 20 39 10MR Blue 34 20 39. SKS Bushed 2 Bushed 112 Bushed 112, Indy XLT 10MW Blue 34 21 39 tOMR Blue 34 20 39 lOMR Blue 340 21 39. SP Bushed 2 Bushed 2 Bushed 2, Indy XLT tOMB Gold 34 20 39 10MW Blue 34 20 39 10MR Blue 34 20 39. Tounng Bushed 2 Bushed 2 Bushed 2, Indy XLT 10MB Gold 34 18 39 tOMW Blue 34 18 39 10MR Blue 34 18 39. RMK Bushed 112 Bushed 2 Bushed 112, Indy 600 tOMW Blue 34 21 39 10MR Blue 34 21 39 10MR Blue 34 21 39.
XCR Bushed 112 Bushed 2 Bushed 112, lnd 600 10 Blue R 1 21 35 10M Blue R 1 21 35 10MB or Blue R 1 21 35. XC SP Bushed 2 Bushed 2 10MW 2, Indy RXL 10 Blue 36 20 35 10MB Blue 34 112 20 35 10MW Blue 34 2 20 35. Bushed 2 Bushed 36 113 Bushed 36 113,9 97 6 4 Polaris Industries Inc. High Elevation Specifications,1996 HIGH ELEVATION RECOMMENDATIONS Cont. 3000 Ft to 6000 Ft 6000 Ft to 9000 Ft 9000 Ft to 12000 Ft. Machine Chain Chain Chain, Model Shift Clutch Driven case Shift Clutch Driven case Shift Clutch Dri ven case.
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix Gearing. Indy Ultra 10M Blue 36 2 1 35 10MB Blue 36 21 35 10MW Blue 36 21 35. SP Bushed 2 Bushed 2 Bushed 112, Indy Ultra 10M Blue 36 20 35 10MB Blue R 9 20 39 10MW Blue R 9 20 39. RMK Bushed 2 Bushed 2 Bushed 2, Indy Ultra 10M Blue 36 20 35 10MB Blue 36 20 35 10MW Blue 36 20 35. SKS Bushed 112 Bushed 2 Bushed 2, Indy Storm 10 58 Blue R 3 23 37 10 56 Blue R 3 2 1 37 10AL Blue R 3 21 3T. Bushed 2 Bushed 112 or Bushed 2 or,20 35 20 35, Indy Storm 10 58 Blue R 3 20 35 10 56 Blue R 3 20 35 10AL Blue R 3 20 35. SKS Bushed 2 Bushed 2 Bushed 2, ln Siorm 10 58 Blue R 3 20 35 10 56 Blue R 3 20 39 10AL Blue R 3 20 39.
R K Bushed 2 Bushed 112 Bushed 2,Cannot be used with reverse kit. Polaris Industries Inc 6 5 9 97,Specifications, 1997 Clutch Specifications 0 3000 Feet 0 900 Meters. Machine Engagement Operating Production Spring Shift WI Driven Clutch Driven Chaincase. Model RPM RPM Drive Color I D Gram Spring Center Helix Gearing. 300 200 ClutchPart Wire Dia Color Distance Angle,No 100 Location. Indy Lite GT 4 100 7000 1321601 Silver Gold 10 Red 11 030 36 5 16 39. Indy Lite Deluxe 1321602 218 B 2, Indy Sport 4000 7000 1321687 Red White 10AL Red 12 00 36 5 17 35. 192 Bushed B 2, Sport Touring 3500 7000 1321594 Brown 10 Red 12 00 36 5 16 39.
Indy TranSport 200 Bushed B 2 15 39, Indy Super Sport 4000 7000 1321659 Red White 10AL Red 12 00 36 21 39. 192 Bushed 112, Indy Trail 3600 7000 1321659 Red White 10AL Red 12 00 36 21 39. Indy Trail Touring 1321660 192 Bushed 2 20 39, Indy Trail RMK 3600 7000 1321683 Red White 10AL Red 12 00 36 19 40. 192 Bushed 2, Indy XCF 4000 7000 1321698 Red White 10 Red 12 00 34 20 39. 192 Bushed 2, Indy WideT rak GT 3800 6500 1321661 Brown 10 Red 12 00 36 19 41.
200 Bushed 2, Indy WideTrak LX 3800 7000 1321692 Brown 10 Red 12 00 36 19 41. 200 Bushed 2, lndy440 LC 3800 7750 1321662 Gold 10MB Red 12 00 34 21 39. 207 Bushed 2, Indy 440 XC 4900 8250 1321686 Dark Blue 10 Silver 12 00 R 8 21 39. 218 Bushed 2, Indy 440 XCR 4900 8250 1321704 Almond S 53R Silver 12 00 R 8 22 41. Gold 207 Bushed 2, Indy 500 4000 7800 1321663 Gold 10M Red 12 00 36 21 39.
lndy500 SKS 7800 207 Bushed 2 20 39,Indy 500 EFI 8000 21 39. Indy 500 RMK 3800 7800 1321655 Gold 10M Red 12 00 36 20 39. 207 Bushed 2, Indy Classic 4000 7800 1321690 Gold 10M Red 12 00 36 21 39. 207 Bushed 2, Indy Classic Touring 4000 7800 1321691 Gold 10MB Red 12 00 34 19 39. 207 Bushed 2, Indy XLT XLT LTD 4200 8000 1321665 Gold 10M Red 12 00 34 21 39. Indy XLTTouring 1321689 207 Bushed 2 20 40,Indy XLT SKS 1321571 20 39.
Indy XLTSP 4200 8300 1321678 Gold 10MB Red 12 00 34 21 39. 207 Bushed 2, Indy XLT RMK 4000 8000 1321656 Blue 10M Red 12 00 34 18 40. 207 Bushed 2, Indy XLT LTD SP 4400 8300 1321665 Gold 10M Red 12 00 34 21 39. 207 Bushed 2, Indy 600 XC 4200 8300 1321693 Dark Blue 10 M Red 12 00 34 21 39. 218 Bushed 2, Indy 600 XCR 4800 8500 1321708 Almond 10 54 Gold 12 00 R 1 21 35. Indy 600 XCR SE square 2, Indy RXL 4000 8000 1321650 Blue 10 AL Red 12 00 36 20 35.
207 Bushed 2, Indy Ultra 4500 8200 1321682 Dark Blue 10 54 Red 12 00 36 21 35. Indy Ultra SP 1321682 218 Bushed 2 21 35,Indy Ultra Touring 1321688 20 35. Indy Ultra SPX 4800 8600 1321708 Almond 10 54 Gold 12 00 R 8 21 35. Indy Ultra SPX SE square Bushed 2, Indy 700 SKS 4200 8000 1321695 Dark Blue 10 60 Silver 12 50 36 20 35. Indy 700 RMK 4200 8000 1321696 Dark Blue 10 60 Silver 12 50 R 11 21 39. 218 Bushed lt2, Indy Storm 4800 8400 1321651 Almond 10 58 Gold 12 50 R 4 23 37. Storm SE RMK 1321658 square Bushed 2 20 39,NOTE RMK production setup is 6000 9000 feet.
9 97 6 6 Polaris Industries Inc,High Elevation Specifications. 1997 HIGH ELEVATION RECOMMENDATIONS, 3000 Ft to 6000 Ft 6000 Ft to 9000 Ft 9000 Ft to 12000 Ft. Machine Chain Chain Chain, Model Shift Clutch Driven case Shift Clutch Driven case Shift Clutch Driven case. Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix Gearing. lnd Lite 10M Gold 36 5 16 39 10M Gold 36 5 16 39 10M While or Blue 36 5 16 39. GT Deluxe Blue B 2 White B 2 10M Red Gold IIB 2, Indy Sport 10 RedJWhite 36 5 17 35 10AL Gold 36 5 16 35 10M Blue or RedJWhite 36 5 16 35. Bushed B 2 Bushed B 2 10 Bushed Gold IIB 2, Indy Sport 10M Brown 36 5 16 39 10M Gold 36 5 16 39 tOM Blue Gold 36 5 16 39.
Touring Bushed B 2 Bushed B 2 Bushed B 2, Indy 10M Brown 36 5 15 39 10M Gold 36 5 15 39 10M Blue Gold 36 5 15 39. TranSport Bushed B 2 Bushed B 2 Bushed iiB 2, Indy Super 10AL RedJWhite 36 21 39 10 Red White 36 20 39 10MB Red White 36 20 39. Sport Bushed 2 Bushed 2 Bushed 2, Indy Trail 10AL Red White 36 21 39 10 Red White 36 21 39 10MB Red White 36 21 39. Touring Bushed 2 20 39 Bushed 2 20 39 Bushed 2 20 39. lnZ Trail 10 RedJWhite 36 19 40 10MB Red White 36 19 40 10MW Red White 36 19 40. R K Bushed 2 Bushed 2 Bushed 3, XCF 10M Red While 34 20 a9 10M Gold a4 16 as 10MB Gold 34 16 a5. Indy WideTrak GT EC50PM03 6600 1321661 Brown 10 200 Bushed Indy WideTrak LX EC50PLE12 7000 1321644 Brown 10 200 Bushed Indy 440 LC EC45PL06 8000 1321580 Gold 10MB 207 Bushed Indy 440 XCR EC45PL07 8250 1321648 Blue 10MB 207 Bushed Indy 440 XCR SP EC45PL08 8250 1a2164a Blue 10M 207 Bushed

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