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

MODELOFTORQUESTOPINSTALLATIONWITHCLUTCHHOUSINGBACKREMOVED

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.