Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 48

 

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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 48

 

 

7.24

PVT System

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

DRIVEN CLUTCH

Driven Clutch Removal

1.

Remove the drive belt.

2.

Apply and lock the parking brake.

3.

Remove the driven clutch bolt and washers (A).

NOTE:  Count the number and location of the spacer
washers located on the fastener and behind the
clutch.

4.

Slide the driven clutch off the jackshaft.

5.

Inspect the splines and replace jackshaft if damage is
found.

Driven Clutch Installation

1.

Install the driven clutch bolt with the same amount of
washers at removal.

2.

Torque the bolt to specification.

3.

Check for correct belt deflection.

A

7.25

PVT System

7

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Team LWT Components

Disassembly and Assembly Process

1.

Remove the screws from the helix, then carefully pry
the helix out of the moveable sheave.

2.

Install the clutch in the clutch compressor fixture, PN
PU-50518.

3.

Wearing eye protection, carefully compress the roller
assembly to gain access to the snap ring. Remove the
snap ring.

4.

Slowly release the fixture arm to remove the roller
assembly and spring. Disassembly the clutch
sheaves.

5.

Inspect the sheaves for abnormal wear. Clean sheave
faces with a Scotch Brite pad and a solution of warm,
soapy water.

6.

Inspect spring, spring cup, spacer and rollers for wear
and replace as required.

7.

To assemble the clutch, slide the components back on
to the stationary sheave shaft.

8.

Align the notch in the roller assembly with row of
double splines on the shaft. Slowly compress the
spring and roller assembly down on to the shaft. Install

the snap ring making sure it is fully seated in the
groove.

9.

Install the helix by aligning the rollers with the ramps.
Push the helix down into the sheave while keeping the
screws holes aligned.

10. Install and torque helix fasteners to 60 - 80 in. lbs. (7

- 9 Nm).

HELIX

SNAP RING

SPRING

SPRING CUP

MOVEABLE SHEEVE

DEFLECTION SPACER

STATIONARY SHEEVE

BELT DEFLECTION SCREW

ROLLER ASSEMBLY

SCREWS

T 

Helix Fasteners = 60 - 80 In.Lbs. (7 - 9 Nm)

Driven Clutch Retaining Fastener = 17 Ft.Lbs. (23 Nm)

CAUTION

Driven spring under pressure. Wear eye protection 

when removing snap ring and helix.

7.26

PVT System

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Widetrak Driven Clutch Components

Disassembly and Assembly Process

1.

Install the clutch into the clutch compression fixture,
PN PU-50518. Slowly compress the helix down into
the sheave to gain access to the snap ring. Remove
the snap ring.

2.

Slowly release the fixture arm to remove the helix and
spring. Disassemble the clutch sheaves.

3.

Inspect the key, spring, bushing and clutch sheaves
for damage. Replace the bushing if more brass than
Teflon in visible.

4.

Clean the sheaves with a Scotch Brite pad and a
solution of warm, soapy water.

5.

Inspect the rollers for abnormal wear and replace as
required. Verify the spring tabs are in alignment and
parallel.

6.

Assemble the clutch by sliding components down on
to sheave shaft.

7.

Insert one leg of the spring into the hole in the sheave.
Insert the other spring leg into the #2 hole in the helix.

NOTE:  Inserting the spring leg into hole #4 in the helix
will increase the amount of pre-tension in the spring.
While this may prevent belt slippage, belt burning or
engine over-revving may result.

8.

Align the helix and stationary keyway. Compress the
helix down onto the shaft enough to prevent the spring
from dis-lodging from the helix and sheave, but do not
engage the rollers.

9.

Hold the stationary sheave and rotate the moveable
sheave 1/4 to 1/3 revolution counterclockwise (until
rollers align with helix ramps).

10. Compress the helix down into the sheave. Install the

key into the keyway, then the washer, then finish with
the snap ring. Verify the snap ring is fully seated in the
groove with the sharp edge upward.

11. Carefully release the clutch compressor arm. Test the

clutch action by rotating the sheaves several times.
The moveable sheave should forcefully “snap” closed
when released.

KEY

SNAP RING

WASHER

HELIX

SPRING

BUSHING

SCREWS

MOVEABLE SHEAVE

ROLLERS

SHIM SPACERS - AS REQUIRED

FLAT WASHER - ALWAYS INSTALLED

DEFLECTION CAM

SCREWS

DEFLECTION PINS

BUSHING

T 

Deflection Cam Screws = 10 ft.Lbs. (12 Nm)

Driven Clutch Retaining Fastener = 17 Ft.Lbs. (23 Nm)

CAUTION

Driven spring under pressure. Wear eye protection 

when removing snap ring and helix.

7.27

PVT System

7

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Polaris P2 Driven Clutch Components

NOTE: Spring Cups - All 2009 550cc driven clutch
assemblies were manufactured with only one spring
cup located in the helix.
Later service part clutch assemblies may feature a
machined recess in the moveable sheave for another
spring cup for a total of two per assembly. Do not
install a spring cup into a non-machined moveable
sheave.

Disassembly and Assembly Process

1.

Remove the driven cover screws and cover. Note the
“X” in the cover and moveable sheave are in
alignment.

2.

Install the clutch into the clutch compression fixture,
PN PU-50518. Screw-down clutch compressors are
commercially available through after-market

companies such as Team Industries Inc.

3.

Remove the snap ring. Verify the washer is not lodged
inside the snap ring groove.

4.

Unscrew the compressor to remove the helix and
spring. Disassemble the clutch sheaves.

5.

Inspect the helix, spring, bushings, rollers, and clutch
sheaves for damage.

6.

The cover and sheave bushings are not serviceable.
If bushings are severely worn or binding, clutch
assembly replacement is required.

7.

Clean the sheaves with a Scotch Brite pad and a
solution of warm, soapy water.

8.

Inspect the rollers for abnormal wear and replace as
required.

9.

Assemble the clutch by sliding components down on
to stationary sheave shaft.

DRIVEN COVER

RETAINING RING

WASHER

HELIX

SPRING

WASHER

ROLLER

MOVEABLE SHEAVE

BUSHING

BUSHING

SPACER

STATIONARY SHEAVE

DEFLECTION PINS / CAM

SPRING CUPS*

* = See Note 

(NO SERVICE)

(NO SERVICE)

T 

Deflection Cam Screws = 12 Ft.Lbs. (16Nm)

Driven Cover Screws = 12 Ft.Lbs. (16Nm)

Driven Clutch Retaining Fastener = 17 Ft.Lbs. (23 Nm)

Roller Fasteners = 110 In.Lbs. (12.5 Nm)

CAUTION

Driven spring under pressure. Wear eye protection 

when removing snap ring and helix.

 

 

 

 

 

 

 

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