model of torque stop installation with clutch … · of the puller slightly will aid in removal. do...
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DURACLUTCHINSTALLATION15-507DCG1-RANGER800-FS
SVI,LLCREV4PART#:15-507 MODEL:DCG1-RANGER800-FSDESCRIPTION:RANGER800FULLSIZEALLMODELSEXCEPTRANGER8006X6 KITCONTENTS: 1 10-071 PRIMARYCLUTCH 2 25-164SHOULDERWASHER,SUPERSEDES90-019 3 10-055 SECONDARYCLUTCH 4 10-059 TORQUESTOPTRANSAXLEMOUNT 5 3211162BELT 6 30-093 TOOL-BELTINSTALL 7 97-008 DECALS-CLUTCHHOUSINGANDDASH3211162 8 OWNERSMANUALSUPPLEMENT9 WEIGHTCHART10 DURACLUTCHWARRANTY 11 INSTALLATIONINSTRUCTIONS15-507(THESEINSTRUCTIONS)
NOTEREGARDINGTHETORQUESTOPANDENGINEMOUNTS:AtorquestopissuppliedwiththisDURACLUTCHkit.Installingthetorquestopisoptional.InstallationisrecommendedifoptimumaccelerationandenginebrakingaredesiredandespeciallyiftheRANGERisusedtocarryorpullheavyloads.Howthetorquestopworks:TheRANGER800engineandtransmissionaremountedindependentofeachother.Theengineisrubbermountedforvibrationisolation.Whentorqueistransmittedthroughthebelttherubbermountsflexandtheengineispulledtowardthesecondaryclutchonthetransmissiontendingtoloosenthebelt.Thepurposeofthetorquestopistolimittheenginemovementwhenacceleratingandenginebraking.Thetorquestopmaintainsbelttensionandkeepsthebeltfromslipping.Enginemounts:Nowisagoodtimetocheckmotormounts(4places)toinsurenonearebroken(separated)orvehicleperformancewillbeadverselyaffected.Thebestwaytodothisistouseaprybartomovetheengineawayfromthemount.Ifthemountisbrokenitwillseparatewhenyoumovetheengineawayfromthemount.Replaceanybrokenmotormounts.Ifyoudecidetoinstallthetorquestopwerecommendinstallationnow,sincemuchoftherequireddisassemblyisalreadydone.IfnotinstallingatthistimeskiptoDURACLUTCHINSTALLATION.
TORQUESTOPINSTALLATION:1. Removeclutchhousingbackandinstallthetorquestopbracketwiththetransaxlemountingboltsas
shown.Torquenutsto32ft-lbf.
PROCEEDURETOSETTORQUESTOP:2. Ifneededtrimhosetoclearpad(noneedtoremovehosetotrim)orloosenthehoseclampand
movethehoseup.Tightentherubberpadagainstenginesothepadjusttouchestheengineonthebottomsideofthepad.Holdrubberpadfromturningandlockjamnut.Theupperpartofthepadshouldnotbetightagainsttheengine.Note:Ifthepadistightagainsttheenginewhenidlingorinsteadystaterunning,undesirableenginevibrationwillbefelt.Whentheengineisacceleratingorinenginebrakingmodeitshouldpullbackagainsttherubberpadtokeepthebelttightsoitwon’tslip.
3. Whenreinstallingclutchhousingbackinsuresealsaregoodorreplace.
PHOTOOFTORQUESTOPINSTALLATIONWITHCLUTCHHOUSINGBACKREMOVED
EngineTransmission
TorqueStopBracket
RubberPad
JamNut
TrimhoseOrmoveup
MotorMount
DURACLUTCHINSTALLATION1. RemovetheSecondaryclutch.2. InstallDURACLUTCHSecondary.Tightenboltto17ft-lbf.3. RemovePrimaryclutchbolt.RemovethePrimaryclutchwithapuller(SVI25-147).Greasingtheend
ofthepullerslightlywillaidinremoval.Donotgetgreaseonanyclutchcomponents.4. Cleantheenginetaperedshaftandprimaryclutchborewithalcoholordegreaser.Donotlubricate.5. SlipthebeltintothePrimaryandovertheSecondary.6. InstallDURACLUTCHPrimarywithshoulderwasherasshown.DONOTUSEtheO.E.flatwasher.It
mayinterferewiththeprimarycover.Tightenboltto60ft-lbf.
7. InstallthebeltasfollowsifthePrimaryandSecondaryclutchesarealreadyinstalled,PlacebeltinthePrimaryandopentheSecondarysheaveswiththeBeltInstallationToolprovided(seephoto).RollthebeltintotheSecondarysheaves.
DURACLUTCHPRIMARYDrive
O.E.PlasticSleeve
ShoulderWasherSVIPN25-164,supersedes90-019SuppliedwithDURACLUTCHKit
DONOTUSEO.E.FlatWasher
O.E.Bolt
O.E.LockWasher
O.E.=OriginalEquipment
8. Setbelttension.Placetransmissioninneutralandsetparkbrake.APPLYFOOTBRAKETOINSUREVEHICLEREMAINSSTATIONARY.ApplyslightthrottletoturnSecondary
9. Installouterclutchhousing.Insuresealisgoodorreplace.TheDURACLUTCHprimaryisslightlylargerthantheoriginalequipmentprimary.Toinsuretheprimarydoesnotrubagainstthecoverpushupandbackonthehousingwhilelightlysnuggingthebottomscrews.Thentightenthetoprearscrewfollowedbytheothertopscrews.Thentightenallremainingscrewsincludingthebottomscrewsevenly.Afterstartingtheengineifyouheartheprimaryrubbing,pushonthecoverwhiletheengineisrunningindifferentdirectionstoseewhichwaywilleliminatetherubbing.Stoptheengineandloosenthehousingscrewsandretightenusingtheabovesequencewhilepushingonthecoverinthedirectionthateliminatedtherubbing.Ifthisdoesnoteliminatetherubbingtryinstallinganewgasketandgothroughthebolttighteningsequenceagain.Ifyoucannoteliminatetherubbingthecoverisheatwarpedandyoumayhavetoinstallanewcoverandperhapsanewbackplate.Youmayalsotryusingaheatguntoremoveheatsaginthecover.
DECALS10. Apply2decalsasshown–1ontheclutchhousingand1onthedash.Cleansurfacewithalcoholor
similarnon-harshsolvent.DecalapplicationisimportanttoalertservicetechniciansthatthestandardPolarisclutcheshavebeenreplaced.