How to Remove Polaris Clutch

The clutch system in a Polaris ATV is critical for transferring power from the engine to the transmission. Removing it for maintenance, upgrades, or repairs may sometimes be necessary. But do you know how to remove Polaris clutch? Or how do you inspect a Polaris clutch?

With our Polaris Sportsman clutch removal guide, we aim to help you through the process efficiently and safely, ensuring you can confidently maintain and repair your ATV!

How to Remove Polaris Clutch

Despite the vital function of the Polaris clutch, many enthusiasts encounter several challenges when removing them due to their complex nature and specific installation requirements. With the right knowledge and the necessary skills, you can efficiently perform the necessary maintenance tasks and repairs independently. 

Whether you require professional support, guidance, or services, our best Polaris dealership at Wickham Tractor offers comprehensive solutions for all your ATV maintenance and repair needs. With that said, here are the steps for removing the clutch from your Polaris:

Preparation

Park your Polaris ATV on a flat, stable surface and engage the parking brake while keeping the ATV in neutral. You can also use jacks to elevate your off road vehicle to further enhance stability and safety. This will prevent accidental movements during the removal procedure.

Next, ensure your engine is turned off and allow it to cool down if it has been running recently. This will avoid the risk of burns or injury from hot components. You can also remove both rear wheels to provide better access to the clutch cover bolts.

Finally, you need to gather all the necessary materials for proper removal procedures. This includes the following:

• Socket wrench set
• Clutch puller
• Screwdrivers
• Clean rags

Remove the frame brace

To remove the frame brace from your Polaris ATV, you first need to locate the bolts securing it. Typically, they are 15mm bolts that require an appropriate socket wrench to unscrew them properly.

Once removed, gently lift the frame brace away from your ATV and place it in a secure area. Be mindful of the bolts and the brace to avoid any damage during removal, ensuring everything can be reinstalled securely when necessary.

Remove the clutch cover

Wondering how to remove Polaris clutch cover? Start by identifying its location, which is generally on the right side of the engine. 

Typically, the clutch cover is secured with bolts or screws. You need to locate and remove the eleven 10mm bolts that hold the cover in place. Using the proper socket, carefully unscrew each bolt.

After that, gently pull off the clutch cover to reveal the clutch assembly underneath. With this step, you will expose the inner clutch system, allowing for further maintenance and inspection. It’s important to organize all the bolts you’ve removed to avoid unnecessary trouble during the reassembly process.

Remove the clutch drive belt

To remove the clutch drive belt, regardless of the Polaris ATV model, you can follow these two effective methods:

Method 1

To remove the clutch drive belt using the first method, you need to start by rotating the driven clutch sheave to locate its opening. Next, insert the span/spreader wrench, with the hook facing the rear of the ATV, into its opening.

Gently push the wrench toward the front of the ATV, releasing the tension on the sheave and making it easier to remove the belt. Now, while maintaining tension with the wrench, carefully remove the belt from around the sheave. It’s important to work patiently and ensure all steps are performed accordingly.

Method 2

In the second method of removing the clutch drive belt, you’ll need to find the access opening by rotating the driven clutch sheave, similar to the first method. Then, insert the span/spreader wrench with the hook facing upwards and carefully push the large end against the lower drive clutch.

Loosen the 15mm bolt located at the center of the driven sheave, releasing tension from the components. This will allow you to remove the belt from the sheave. Proceed with caution to avoid damaging any parts of your ATV.

Remove the clutch

To remove the clutch from your Polaris ATV, you’ll need a socket wrench to loosen the main clutch bolt in the center of the assembly by turning it counterclockwise. Next, attach a clutch puller tool to the clutch assembly. 

After that, turn the tool clockwise and carefully pull the clutch off the crankshaft. Once the clutch is out, lift it off the crankshaft and inspect it for any signs of damage or wear and tear.

Reinstallation

Finally, if you’re not replacing the clutch immediately, it’s important to ensure all parts are kept clean and organized for reinstallation. However, if you’re replacing the clutch in your Polaris ATV, you must follow proper reinstallation procedures and torque specifications as per your ATV’s manufacturer manual.

How to Remove Polaris Secondary Clutch and Primary Clutch

The secondary clutch requires no additional tools beyond a socket to remove the bolt. But do you know how to remove Polaris clutch without puller?

To remove the secondary clutch, unscrew the center bolt with the 15mm socket. Once the bolt is removed, you can easily slide the driven clutch off the shaft, ensuring no small components are lost during the process.

For the primary clutch, you need to loosen the center bolt with an 18mm socket, using a drive extension to keep the clutch steady. After removing the bolt, insert a clutch drive puller into the opening and turn it with a 22mm socket until the clutch breaks loose. Lastly, slide the clutch off the shaft.

Conclusion

Understanding how to remove Polaris clutch is critical for maintenance requirements, damage inspections, and repair necessities. By following our steps, you can confidently and effectively remove the clutch from your ATV. 

We advise you to always prioritize safety and take necessary precautions to avoid injury or damage to your vehicle. Make sure to seek further guidance in the manufacturer manual for specifications and accurate steps.