duraclutch installation 15-509 dcg1-ranger900-a · 2017-12-01 · 15-509 dcg1-ranger900-a svi, llc...

DURACLUTCHINSTALLATION15-509DCG1-RANGER900-A

SVI,LLCREV7 PART#:15-509 MODEL:DCG1-RANGER900-ADESCRIPTION:MY14RANGER900ALLMODELS,MY15RANGER900CREWKITCONTENTS: 1 10-071 PRIMARYCLUTCH 2 10-063 SECONDARYCLUTCH 3 3211149BELT (Supersededfrom3211172) 4 30-093 TOOL-BELTINSTALL 5 97-009 DECALS-CLUTCHHOUSINGANDDASH3211149 6 OWNERSMANUALSUPPLEMENT7 WEIGHTCHART8 DURACLUTCHWARRANTY 9 INSTALLATIONINSTRUCTIONS15-509(THESEINSTRUCTIONS)

DURACLUTCHINSTALLATION1. RemovetheSecondaryclutch.2. InstallDURACLUTCHSecondary.IfthereisasnapringbehindtheSecondary,removeit.Tightenbolt

to48ft-lbf.3. SlipthebeltintothePrimaryandovertheSecondary.4. RemovePrimaryclutchbolt.RemovethePrimaryclutchwithapuller(SVI25-127/PII28772085).

Greasingtheendofthepullerslightlywillaidinremoval.Donotgetgreaseonanyclutchcomponents.

5. CleantheenginetaperedshaftandPrimaryclutchborewithalcoholordegreaser.Donotlubricate.6. InstallDURACLUTCHPrimarywithshoulderwasherasshown.DONOTUSEtheO.E.flatwasher.It

mayinterferewiththePrimarycover.Tightenboltto60ft-lbf.

7. InstalltheBeltasfollowsifthePrimaryandSecondaryarealreadyinstalled.PlaceBeltinthe

PrimaryandopentheSecondarysheaveswiththeBeltInstallationToolprovided(seephoto).RollbeltintotheSecondarysheaves.

DURACLUTCHPRIMARYDrive

DONOTUSEO.E.FlatWasher

O.E.Bolt

O.E.LockWasher

O.E.=OriginalEquipment

O.E.SHOULDERWASHER

8. Setbelttension.PlacetransmissioninPARK!APPLYFOOTBRAKETOINSUREVEHICLEREMAINSSTATIONARY.ApplyslightthrottletoturnSecondary.

9. Installouterclutchhousing.Insuresealisgoodorreplace.TheDURACLUTCHprimaryisslightlylargerthantheoriginalequipmentprimary.Toinsuretheprimarydoesnotrubagainstthecoverpushupandbackonthehousingwhilelightlysnuggingthebottomscrews.Thentightenthetoprearscrewfollowedbytheothertopscrews.Thentightenallremainingscrewsincludingthebottomscrewsevenly.Afterstartingtheengineifyouheartheprimaryrubbing,pushonthecoverwhiletheengineisrunningindifferentdirectionstoseewhichwaywilleliminatetherubbing.Stoptheengineandloosenthehousingscrewsandretightenusingtheabovesequencewhilepushingonthecoverinthedirectionthateliminatedtherubbing.Ifthisdoesnoteliminatetherubbingtryinstallinganewgasketandgothroughthebolttighteningsequenceagain.Ifyoucannoteliminatetherubbingthecoverisheatwarpedandyoumayhavetoinstallanewcoverandperhapsanewbackplate.Youmayalsotryusingaheatguntoremoveheatsaginthecover.

10. DECALS11. Applytwodecalsasshown–oneontheclutchhousingandoneonthedash.Cleansurfacewith

alcoholorsimilarnon-harshsolvent.DecalapplicationisimportanttoalertservicetechniciansthatthestandardPolarisclutcheshavebeenreplaced.