CHAPTER 7

TORQUE-O-MATIC DRIVE
Drive Belt Part Numbers and Application ............ ... .. ...... ....... .. . .... .. 7.1
P-85 Drive Clutch Information
1972-1984 .... .. .... .. ........... .... .. .... .... ... ..... . ............. ... 7.2
1985-1988 ............................ ... . .. . .. ......................... 7.3
1989-1990 ....................... ......... .... . ........ .. ..... .. ..... . .. 7.4
1991-1992 ............................................................... 7.5
1993-1994 ......................................... .. .... ..... .. .... .. .. 7.6
1995 .... .... .. .. ....................................................... 7.7
Service Tools .............................. . ................................ 7.8
Operation .... .. ......................................... . ........ ... ... 7.9-7.11
Data
1985 .......................... . ....... . ............................ .. . 7.12
1986 .................................................................. 7.13
1987 .................................................................. 7.14
1988 . ....... .. ... .... . ............................ . ................... 7.15
1989 ....................... . ................................ . ........ . 7.16
1990 .... ..... ....... . . .............. . ............... ... ..•.......... ... 7.17
1991 ............. .. ................. ..... ... .. ....... ...... ... ... ... . 7.18
1992 .. ... .. . .... ... ... .. ... ... . .. .................. .. ............. 7.19-7.20
1993 ...................................................... . . ..... . 7.21-7.22
1994 ............................................. .. ............... 7.23-7.24
1995 .............................................................. 7.25-7.26
Drive Clutch Service Parts . ... .................... ..... . .. ... .... . .. .... .... 7.27
Drive Clutch Weight Identification - Actual Size ........ . ..... .. ............. 7.28-7.31
Drive Clutch Spring Rates ......... .. .. .. . :\ ............... . ....... . .......... 7.32
Drive Clutch Spring Data ......... ... ..................... .. ...... . .......... 7.33
Drive Belt Adjustments ... .. ............... . ...... . ... .. ................. 7.34-7.35
Clutch Alignment ................ ... .. . .................. . ..... .. ........... 7.36
P-85 Drive Clutch . . ............... . ... . ............ .. ...................... 7.37
Drive Clutch Identification and Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.38
Drive Clutch Disassembly and Inspection . .. ... .. . ... ........ ... . ... ...... 7.39-7.40
Spider Assembly ...................................... . ................ 7.41-7.43
Spider Indexing ......................... .. : ..................... . ...... 7.44-7.45
Aluminum Driven Clutch Service P-85 ........... . ... : ....... . . .. .. ... .... 7.46-7.47
Aluminum Driven Clutch Service P-90 ...... ........ . .. ....... .. . .... ... . ..... 7.48
Troubleshooting ... .... ... . ...... .. .................................. . . 7.49-7.50
"
8/94
I
I
t
l
, 1/ '
o
....
, -
c
TORQUE-O-MATIC DRIVE
Drive Belt Part Numbers and Applications
3211042 ..... Allindys except Indy Sports, Indy lites, Star 1985-1990, Star Trak 1987-1990,
Long T rak 1985-1989
3211045 ..... Close tolerance version of 3211042
3211046 ..... Sport and Sport GT 1987-1991 with P85 Clutch
3211051 ..... lite 1991-1992
3211052 ..... Sport, Sport GT, and Starlite Pilot Build 1990 with P90 Clutch
3211054 ..... Sport, Sport GT 1991-1992
3211055 .... . StarLite 1991-1992
3211053 ..... . lite GT 1992
3211058 ..... lite, lite GT 1993-1995
3211060 . . ... StarLite 1993-1995
3211057 ..... Storm 1993-1995
:'
7.1
8/94
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch Information
1972 - 79 Models
MODEL
ALL MODELS
1980 Models
MODEL
GEMINI 250
APOLLO 340
GALAXY 340
GALAXY 440
TXfTX-C 340
TX 440
TX-L 340
CENTURION 500
TX-L INDY 340
1981 Models
MODEL
GEMINI 250
GALAXY 440
CUTLASS 340
CUTLASS SS 340
TX-C 440
TX-L 340
CENTURION INDY 500
1982 Models
MODEL
GEMINI 250
CUTLASS SS 440
TX-C 440
TX-L 340
TX-L INDY
CENTURION
1983 Models
MODEL
GEMINI 250
STAR 250
SPORT 440
SS 440
TRAIL 440
INDY CC 340
600
LONG TRACK 440
1984 Models
MODEL
STAR 250
SS440
TRAIL 440
600
STAR 250/LT
LONG TRACK 440
400
8/94
SERVICE CLUTCH NO. BASIC NO.
1321471 20
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321471 20
1321470 .... 19
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321471 20
1321471 20
1321440 13
1321470 19
1321470 19
1321471 20
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321440 13
1321470 19
1321470 19
1321 470 19
1321471 20
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321471 20
1321440 13
1321440 13
1321440 13
1321470 19
1321471 21
1321440 13
SERVICE CLUTCH NO. BASIC NO.
1321471 20
1321463 17
1321463 17
1321480 21
1321471 20
1321440 13
1321440 13
7.2
au
1985 Models
c
MODEL
STAR 250
SS440
TRAIL 440
400
600
LONG TRACK 440
1986 Models
MODEL
STAR
SPRINT
SS440
TRAIL 488
400
600
600 LE
LONG TRACK 440
1987 Models
MODEL
STAR
STARTRAK
SPRINT
SPRINT ES
SPORT
TRAIL
TRAIL (ES)
TRAIL 133 SKS
400
400133 SKS
600
LONG TRAK REV 440
1988 Models
MODEL
STAR
STARTRAK
SPRINT ES
SPORT
TRAIL & TRAIL DELUXE (ES)
TRAIL (ES)
TRAIL SKS
400
400 SKS
CLASSIC
650
650 SKS
LONG TRACK REV 440
SERVICE CLUTCH NO.
1321440
1321463
1321463
1321481
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321493
1321463
1321463
1321481
1321480
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321440
1321493
1321493
1321463
1321463
1321463
1321463
1321515
132151 5
1321480
1321440
SERVICE CLUTCH NO.
1321440
1321440
1321493
1321463
1321463
1321463
1321463
1321515
1321515
1321516
1321480
1321480
1321440
7.3
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch Information
BASIC NO.
13
17
17
22
21
13
BASIC NO.
13
23
17
17
22
21
21
13
BASIC NO.
13
13
23
23
17
17
17
17
25
25
21
13
BASIC NO.
13
13
23
17
17
17
17
25
25
26
21
21
13
8/94
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch Information
1989 Models
MODEL
STAR
STAR TRAK
SPRINT ES
LONG TRAK REV 440
SPORT
SPORTGT
TRAIL & TRAIL DELUXE (ES)
TRAIL (ES)
TRAILSKS
TRAILSP
400
500
500 SKS
500 CLASSIC (ES)
500SP
650
650 SKS
1990 Models
MODEL
STAR
STAR TRAK
SPRINT ES
SPORT
SPORT (P-90 BASIC)
SPORTGT
SPORT GT (P-90)
TRAIL & TRAIL DELUXE (ES)
SUPERTRAK
400
500
500 SKS
500 CLASSIC (ES)
500SP
WIDETRAK
650
650 SKS
8/94
SERVICE CLUTCH NO. BASIC NO.
1321440 13
1321440 13
1321493 23
1321440 13
1321463 17
1321463 17
1321463 17
1321463 17
1321463 17
1321463 17
1321481 22
1321515 25
1321515 25
1321516 26
1321515 25
1321480 21
1321480 21
SERVICE CLUTCH NO. BASIC NO.
1321463 17
1321463 17
1321493 23
1321463 17
1321512 24
1321463 17
1321512 24
1321463 17
1321463 17
1321481 22
1321515 25
1321515 25
1321516 26
1321515 25
1321 463 17
1321480 21
1321480 21
7.4
i t:J
c
1991 Models
MODEL
STARLITE
LITE
SPORT & SPORT GT
TRAIL & TRAIL DELUXE (ES)
SUPERTRAK
LITE GT
400 XC
400
500
500 SKS
500 SP
500 CLASSIC (ES)
WIDETRAK
650
RXL
1992 Models
MODEL
STARLITE
LITE & LITE DELUXE
LITE GT
SPORT & SPORT GT
TRAIL & TRAIL DELUXE
WIDETRAK & SUPERTRAK
440
440 XCR
500
500 SKS
500 SP
CLASSIC (ES)
650
RXL
RXL SKS
SERVICE CLUTCH NO.
1321538
1321538
1321512
1321463
1321463
1321512
1321481
1321481
1321515
1321515
1321515
1321516
1321463
1321480
1321480
SERVICE CLUTCH NO.
1321538
1321538
1321512
1321512
1321548
1321548
1321549
1321549
1321549
1321549
1321549
1321550
/
1321551
1321551
1321551
7.5
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch Information
BASIC NO.
27
27
24
17
17
24
29
22
25
25
25
26
17
21
21
BASIC NO.
27
27
24
24
~ _ r !
28
..
28
29
29
29
2!1
29
30
31
31
31
8/94
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch Information
1993 Models
MODEL
STARLITE
STARLITE GT
INDY LITE
INDY LITE DELUXE
LITE GT
SPORT
TRAIL DELUXE
TRAIL
WIDETRAK
440 LIQUID INDY
440 LIQUID SKS
440 XCR
CLASSIC TOURING
CLASSIC
500 EFI
500 SKS
XLT
XLT SKS
XLTSP
RXL
RXL SKS
STORM
STORM SKS
XLT (ELECTRIC START)
1994 Models
MODEL
STARLITE
STAR LITE GT
INDY LITE
INDY LITE DELUXE
LITE GT
SPORT
SUPER SPORT
TRAIL DELUXE
TRAIL
WIDETRAK LX
440 LIQUID INDY
440 LIQUID SKS
CLASSIC TOURING
CLASSIC
500 EFI
500 SKS
XLT
XLT SKS
XLT SP
RXL
STORM
STORM SKS
RXL TOURING
SPORT SKS
WIDETRAKGT
440 XCR
8/94
SERVICE CLUTCH NO. BASIC NO.
1321538 27
1321538 27
1321538 27
1321538 27
1321538 27
1321538 27
1321538 27
1321573 34
1321573 34
1321576 36
1321576 36
1321576 36
1321575 35
1321576 36
1321576 36
1321576 36
1321577 37
1321577 37
1321577 37
1321578 38
1321578 38
1321590 41
1321590 41
1321582 40
SERVICE CLUTCH NO. BASIC NO.
,
1321596 42
1321596 42
1321596 42
1321596 42
1321596 42
1321596 ,../ 42
1321596 42
1321597 43
1321597 43
1321597
,/
43
1321 576 36
1321576 36
1321609 44
1321609 44
1321576 44
1321576 44
1321577 37
1321577 37
1321577 37
1321578 38
1321 623 48
1321623 48
1321610 45
1321596 42
1321597 43
1321576 36
7.6
1995 Models
c
MODEL
STARLITE
INDY LITE
INDY LITE DELUXE
LITE GT
SPORT
SPORT TOURING
SUPER SPORT
TRAIL DELUXE
TRAIL
440 LIQUID INDY
440 LIQUID SKS
440 XCR
WIDETRAK LX
WIDETRAK GT
CLASSIC
500 CARB
500 EFI
500 EFI SKS/PT
XLTTOURING
XLT
XLT SKS/PT
XLTSP
RXL LT
RXL TOURING
STORM
STORM SKS/PT
)
SERVICE CLUTCH NO.
1321596
1321596
1321596
1321596
1321596
1321596
1321596
1321597
1321611
1321576
1321576
1321634
1321597
1321597
1321609
1321609
1321576
1321576
1321609
1321577
1321577
1321577
1321627
1321610
1321623
1321623
7.7
TORQUE-O-MATle DRIVE
P-85 Drive Clutch Information
BASIC NO.
42
42
42
42
42
42
42
43
46
36
36
50
43
43
44
44
36
36
44
37
37
37
49
45
48
48
8/94
TORQUE-O-MATIC DRIVE
Service Tools
A WARNING: All drive clutch maintenance, disassembly and assembly must be performed only by an
authorized Polaris dealer who has attended current model Dealer Service Seminars; has received a certificate of
completion and displays the Polaris Servicing Dealer decal.
Because of the critical nature and precision balance incorporated into the drive clutch, it is absolutely essential that
no attempt at clutch disassembly and/or repair be made without factory authorized tools and service procedures.
Drive Clutch Essential Tools
Description Part Number
Offset Alignment Tool- 21/32" (1.7 cm) P-90 Clutches . .. .... 2870914
Offset Alignment Tool - 5/8" (1 .6 cm) P-85 Clutches ...... . .. 2870426
''T'' Handle Clutch Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2870506
Strap Wrench . . ..... .. ..................... .. .... . ... .. 2870336
Strap Replacement ............... .. .............. ... .. . 2870389
Spider Spanner Nut Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2870338
Spider Torquing Tool ........................... .. .. ... .. 2870341
Holding Fixture Tab ...... . .... .... ....... . .... . .. ...... . 5130518
Holding Fixture .. . .... ... . .... .. .. .... .. ...... . .... . . . .. 2870547
Torque Wrench, 250 ft. lb. . . .. . ....... .. .... ...... ....... Not available through Polaris
Clutch Lubricant .. . ........ .. .. .. ........ ...... . ........ 2870510
Torque Wrench, 0-600 in. lb. ....... . .... . ............. . .. Not available through Polaris
Tapered Reamer ... .. ...... . .. . .. .... ... ... ........ .. .. 2870576
Spider Button Tool ...... . ... ... . .. .......... . . ... .. . .... 2870985
Clutch Bushing Rebuild Tool Kit .. ... ... . . ... . ..... ..... .. 2871025
P-85 Compression Tool .. . .. . ..... . ........ .. ..... . . ... . 2870984
Driven Clutch Puller ........ ... ... ....... . .. ............ 2871056
8/94
7.8
c
TORQUE-O-MATIC DRIVE
Operation
The Polaris torque-o-matic drive system is a centrifugally actuated variable speed belt drive unit. The drive clutch,
driven clutch, and belt make up the torque converter system. Each clutch comes from the factory with the proper
internal components installed for its specific engine model. Therefore, modifications or variations of components
at random are never recommended. Proper converter setup and adjustments of existing components must be the
primary objective in converter operation diagnosis.
A CAUTION: All converter maintenance repairs must be performed only by an authorized Polaris service
technician who has attended a Polaris sponsored service training seminar and understands the proper
procedures as outlined in this manual. Because of the critical nature and precision balance incorporated into the
drive clutch, it is absolutely essential that no attempt at clutch disassembly and/or repair be made without factory
authorized special tools and service procedures. Any unauthorized modifications to clutches, such as adding or
removing weights, will void the warranty.
Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM
The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from
the engine to the ground. This is accomplished by weights and a spring inside the unit which react to the
centrifugal force from the engine RPM.
The spring and weights work in combination. In a properly set up clutch, the maximum desired operating RPM will
be reached immediately after clutch engagement, under full throttle conditions. To gain optimum power this RPM
should be maintained. As centrifugal force pushes the weights against the rollers, the moveable sheave will force
the belt to climb up the drive clutch sheave and increase vehicle speed.
9000--------------------------
8000 ,r ------
______ RANGE 250 RPM __ _

6000-------------4------------
,
SOOO----------.r'--------------
ENGAGEMENT
3000------------------------
If the weights are too light, or the spring rate too high, the maximum RPM will be too great and the drive belt will not
move into high gear at the top of the clutch.
7.9
8/94
TORQUE-O-MATIC DRIVE
Operation
9000-------------------------
8000--------------------------
______ ENGINE OPERATING RANGE ±250 RPM
7000-------------------------
6000 --------------- --
a: 5000 ,7
- .......
ENGAGEMENT 4000-------------------------
3000-----------------------
If the weights are too heavy, or spring rate too low, the engine RPM will be low and the drive clutch will upshift too
fast, keeping the engine out of its power band.
9000-------------------------
8000-------------------------
7000-------------------------
----7"'l1--- - - - - - - ENGINE OPERATING RANGE ±250 RPM
6000 7


3000--------------------------
If the weights and spring are matched properly, the engine RPM will go to the desired range and remain there
on both upshift and backshift.
8/94
7.10
TORQUE-O-MATIC DRIVE
Driven Clutch Operation
The driven clutch operates in conjunction with the drive clutch. Its function is to maintain drive belt tension, pre-
venting slippage and to sense variations in load requirements necessary to maintain optimum engine torque out-
put and load requirements from the track. Output torque is transmitted through the chaincase jackshaft and chain-
case to the front drive shaft and track.
When the load on the driven clutch is increased and becomes greater than the torque delivered from the engine,
the driven clutch becomes dominant and overrides the drive clutch. The driven clutch downshifts into a ratio which
will supply the amount of torque needed for the increased load.
Because the driven clutch can sense and shift into the proper ratio, engine RPM will remain within the specified
range.
Driven Clutch Adjustments
The aluminum driven clutch has a provision for varying the torque requirement to change its ratio. To do this, it
relocates the spring in the helix which in turn increases or decreases the amount of load required to change the
ratio.
Aluminum Driven Clutch
7.11
8/94
TORQUE-O-MATIC DRIVE
Data
1985 PRODUCTION SETUP
Machine Engine Model Operating Production Spring Shift wt. Bore Taper Clutch Driven
Model RPM±200 Clutch Color, I. D.lG ram Diameter Center Helix
Part No. Wire Dia. Distance Angle
Star EC25PS-06 6300 1321449 Brown 08/47.5 1. 174" 12.0" 36·
.200"
SS EC44-2PM-3100 6000 1321450 White 07/52.0 1.174" 11.5" 36·
.17T'
Trail EC44-2PM-2100 6800 1321455 Brown N-1 Mod. 1.174" 12.0"
34·
.200" 51.5
400 EC40PL-02 7800 1321459 Gold N-1 Mod. 1.174" 12.0"
34·
.20T' 51.5
600 EC60PL-02 7800 1321458 Gold 05/53.5 1.17T' 12.0"
34·
.20T'
LongTrak EC44-2PM-5000 6300 1321454 Yellow 04/57.5 1.174" 12.0" 36°
.192"
1985 HIGH ELEVATION RECOMMENDATIONS
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shift Weight Clutch Spring Driven Chaincase
Spring Helix Gearing Helix Gearing
Star 08 Brown 36·
.....
08 Red/white 36·
.....
SS 07 Orange 36·
.....
07 Orange 36·
*_ft ••
Indy Trail N-1 Mod. Gold 34· 19/35 N-1 Mod. Gold 34· 19/35
Indy 400 P-1 Red 34· 19/35 P- 1 Red 34· 19/35
600 06
'.
Blue 34· 21/35 06 Blue 34· 19/35
LongTrak 04 Orange 36· 19/39 04 Silver 36· 19/39
8/94
7.12
Gearing
Chain
Pitch/Type
Direct
Drive
Direct
Drive
19/35
64P Silent
19/35
19/35
63P Silent
19/39
64P Silent
Options-
Non-
Warranty
.....
6 Tooth
Front
Sprocket
ft ••••
ftft •••
** •••
* ••••
c
Machine Engine Model
Model
Star EC25PS-06
Sprint & EC34-2PM-01/02
Sprint ES
SS EC44-2PM-3100
Trail EC50PM-01
Indy 400 EC40PL-02
c
600, EC60PL-02
600 LE
LongTrak EC44-2PM-5100
Machine
Model
Shift Weight
Star 08
Sprint & Sprint ES 05
SS 07
Indy Trail M-1 Mod.
Indy 400 M-1 Mod.
600, 06
600 LE
LongTrak 04
TORQUE-O-MATIC DRIVE
Data
1986 PRODUCTION SETUP
Operating Production Spring Shift wt. Bore Taper Clutch Driven Gearing
RPM±200 Clutch Color, LD./Gram Diameter Center Helix Chain
Part No. Wire Dia. Distance Angle Pitch/Type
6300 1321449 Brown 08/47.5 1.174 12.0" 36· Direct
.200 Drive
6500 1321451 Brown 05/53.5 1.174 11.5" 36· Direct
1321456 .207 Drive
6000 1321450 White 07/52. 0 1.174 11.5" 36· Direct
.177 Drive
7000 1321461 RedlWhite 10/51.5 1.174 12.0" 36· 21/35
.192
- -
7700 1321459 Blue 10/Mod. 1.174 12.0" 34·
19/35
.207 50.0
7800 1321458 Blue/Gold 15/55.5 1.177 12.0" 34·
21/35
.207
6000 1321454 Yellow 04/57.5 1.174 12.0" 36° 19/39
.192
1986 HIGH ELEVATION RECOMMENDATIONS
5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Clutch Driven Chaincase Shift Weight Clutch Spring Driven Chaincase
Spring Helix Gearing Helix Gearing
RedlWhite 36·
...........
08 RedlWhite 36·
Blue/Gold 36· *****
06 Blue/Gold 36·
... ** ....
Orange '36· *****
06 RedlWhite 36· *****
Orange 36· 21/35 M-1 Mod. RedlWhite 36· 21/35
Gold 34· 19/35 P-1 or M-1 Red or 34· 19/35
Mod. Blue/Gold
Blue/Gold 34· 21/35 06 Blue/Gold 34·
21/35
Orange 36· 19/39 04 Silver 36· 19/39
7.13 8/94
TORQUE-O-MATIC DRIVE
Data
Machine Engine Model Operating
Model RPM±200
"
Star EC25PS-06 6300
StarTrak
Sprint & EC34-2PM-01/02 6500
Sprint ES
Indy Sport EC34-2PM-03 6500
Trail (All) EC50PM-01 7000
Indy 400 EC40PL-02 7700
600 EC60PL-02 7800
LongTrak EC44-2PM-5100 6000
(RLR)
1987 PRODUCTION SETUP
Production Spring Shift Wt. Bore Taper
Clutch Color, I. D.lG ram Diameter
Part No. Wire Dia.
1321449 Brown 08/47.5 1.174
.200
1321451 Gold 05/53.5 1.174
1321456 .207
1321461 RedlWhite 10/51.7 1.174
.192
1321477 RedlWhite 10/51.7 1.174
.192
1321459 Blue/Gold 101M 1.174
.207 49.5
1321458 Blue/Gold 10/A 1.177
.207 55.0
1321454 Yellow 04/57.5 1.174
.192
1987 HIGH ELEVATION ijECOMMENDATIONS
Clutch Driven
Center Helix
Distance Angle
12.0" 36·
11.5" 36·
11.5"
34·
12.0" 36·
12.0" 34·
12.0" 34·
12.0" 36°
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shift Weight Clutch Spring Driven
Spring Helix Gearing Helix
Star 08 RedlWhite 36·
. .,...*.
08 RedIWhite 36·
Star Trak
*****
Sprint & Sprint ES 05 Blue/Gold 36· *****
06 Blue/Gold 36·
Indy Sport 10 Gold 34·
17/35 10 Blue/Gold 34·
Indy Trail (All) M-1 Mod. Orange 36· 21/35 M-1 Mod. RedIWhite 36·
Indy 400 M-1 Mod. Gold 34· 19/35 P-1 or M-1 Red or 34·
Mod. Blue/Gold
600 06 Blue/Gold 34· 21/35 06 Blue/Gold 34·
04 Orange 36· 19/39 04 Silver 36·
(RL )
8/94
7.14
Gearing
Chain
PitchfType
Direct
Drive
15/39
Direct
Drive
17/35
21/35
19/35
21/35
)
19/39
Chaincase
Gearing
D. Drive
15/39
*****
17/35
21/35
19/35
21/35
19/39
c
Machine Engine Model
Model
Star EC25PS-06
StarTrak
Sprint ES EC34-2PM-02
Indy Sport EC34-2PM-03
Trail (All) EC50PM-01
Trail SKS
400 Classic EC40PL-02l03
Indy 400
400 SKS
650 EC65PL-01
650 SKS
LongTrak EC44-2PM-4100
(RLR)
Machine
Model
Shift Weight
Star 08
Star Trak
o
Sprint ES 05
Indy Sport 10
Indy Trail (All) M-1 Mod
Trail SKS or 10M
400 Classic 10M Red
Indy 400
400 SKS
650 10M Blue
650 SKS
LongTrak 10
(RLR)
)
TORQUE-O-MATIC DRIVE
Data
1988 PRODUCTION SETUP
Operating Production Spring ShiftWt. Bore Taper Clutch Driven Gearing
. RPM±200 Clutch Color, LD.!Gram Diameter Center Helix Chain
Part No. Wire Dia. Distance Angle PitchfType
6300 1321449 Brown 08/47.5 1.174 12.0" 36· Direct
.200 Drive
15/39
6500 1321456 Gold 05/53.5 1.1 74 11.5" 36· Direct
.207 Drive
6500 1321461 RedlWhite 10/51.7 1.174 11.5" 34·
17/35
.192
7000 1321461 RedlWhite 10/51.7 1.174
./
12.0" 36· 21/35
.192 19/35
8000 1321485 Blue 10M 1.174 12.0" 34· 19/35
1321459 .207 Blue/47.5 19/35
1321459 18/35
7800 1321458 Gold 10/A 1.177 12.0" 34·
21/35
.207 55.0 19/35
6300 1321478 Sil ver 10A 1.174 12.0" 36° 19/39
.208 55.0
1988 HIGH ELEVATION RECOMMENDATIONS
5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Clutch Driven Chaincase Shift Weight Clutch Spri ng Driven Chaincase
Spring Helix Gearing Heli x Gearing
RedlWhite 36·
*"" •••
08 RedlWhite 36·
. ....
15/39 15/39
Blue 36·
""*ft.*
06 Blue 36· *""""--
Gold 34·
17/35 10 Blue 34·
17/35
Orange 36· 21/35 10M Red RedlWhite 36· 21/35
RedlWhite 19/35 19/35
Blue 34·
19/35 10M Red Blue 34·
19/35
19/35 19/35
19/35 19/35
Red 34· 21/35 10M White Blue 34·
21/35
19/35 19/35
Silver 36· 19/39 10 Silver 36· 19/39
7.15 8/94
TORQUE-O-MATIC DRIVE
Data
Machine Engine Model Operating
Model RPM±200
Star EC25PS-06 6300
StarTrak
Sprint ES EC34-2PM-02 6500
Indy Sport, EC34-2PM-03 6500
GT
Indy Trail EC50PM-03 6600
Super Trak
Trai l (All) EC50PM-01/02 7000
Trail SKS
Indy 400 EC40PL-02 8000
Indy 500 EC50PL-01/02 7800
SKS
Classic
650 EC65PL-01 7800
650SKS
LongTrak EC44-2PM-4100 6300
(RLR)
1989 PRODUCTION SETUP
Production Spring Shift Wt. Bore Taper
Clutch Color, I.D.lGram Diameter
Part No. Wire Dia.
1321449 Brown 08/47.5 1.174
.200
1321493 Brown 05/53.5 1.174
.207
1321461 RedlWhite 10/51.7 1.174
.192
1321461 Brown 10/51.7 1.174
.200
1321461 RedlWhite 10/51.7 1.174
.192
1321459 Blue 10M 1.174
47.5 Blue/47.5
1321459 Silver 10M 1.174
1321459 .208
1321493
1321458 Gold 10/A 1.177
.207 55.0
1321478 Silver 10A 1.174
.208 55.0
1989 HIGH ELEVATION RECOMMENDATIONS
Clutch Driven
Center Helix
Distance Angle
12.0" 36"
11.5" 36"
11.5" 34"
12.0" 36"
12.0" 36"
12.0" 34"
12.0" 36"
12.0"
34·
12.0" 36°
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shift Weight Clutch Spring Driven
Spring Heli x Gearing Helix
Star 08 RedlWhite 36"
.****
08 RedlWhite 36"
Star Trak 15/39
Sprint ES 05 Blue 36"
.* •••
06 Blue 36"
Indy Sport, GT 10 Gold 34" 17/35 10 or Blue or 34"
10M Blue Gold
SuperTrak 10M RedlWhite 36" 21/39 10M Blue RedlWhite 36"
Indy Trail (All) M-1 Mod Orange 36" 21/35 10M Red RedlWhite 36"
Trail SKS or 10M RedlWhite 19/35
Indy 400 10M Red Blue 34" 19/35 10M Red Blue 34"
Indy 500 10M Blue Blue 36" 19/35 10M Blue Blue 36"
500 SKS 18/35
650 10M Blue Red 34" 21/35 10M Blue Blue 34"
650 SKS 19/35
LongTrak 10 Silver 36" 19/39 10 Silver 36"
(RLR)
8/94
7.16
Gearing
Chain
PitchfType
Direct
Drive
15/39
Direct
Drive
17/35
21/39
21 /35
19/35
19/35 )
19/35
18/35
19/35
21/35
19/35
19/39
Chaincase
Gearing
•••• *
15/39
*****
17135
21/39
21/35
19/35
19/35
19/35
18/35
21 /35
19/35
19/39
c
Machine Engine Model
Model
Star EC25PS-06
StarTrak
Sprint ES EC34-2PM-02
Indy Sport. EC34-2PM-03
GT
Indy Trail EC50PM-03
Super Trak
Indy Trail EC50PM-01/02
(All)
Indy 400 EC40PL-02
Indy 500 EC50PL-01/02
SKS
Classic
WideTrak EC50PL-03
650 EC65PL-01
650 SKS
Machine
Model
Shift Weight
Star 08
Star Trak
Sprint ES 05
Indy Sport. GT 10
SuperTrak 10M
Indy Trail 10M
(All)
Indy 400 10M Red
Indy 500 10M Blue
500 SKS
WideTrak 10M Blue
650 10M Blue
650 SKS
TORQUE-O-MATIC DRIVE
Data
1990 PRODUCTION SETUP
Operating Production Spring Shift WI. Bore Taper Clutch Driven Gearing
RPM±200 Clutch Color. I.DJGram Diameter Center Helix Chain
Part No. Wire Dia. Distance Angle Pitch/Type
6300 1321463 Brown 08/47.5 1.174 12.0" 36· Direct
.200 Drive
15/39
6500 1321493 Brown 05/53.5 1.174 11 .5" 36· Direct
.207 Drive
6500 1321463 RedlWhite 10/51.7 1.174 11 .5"
34·
17/35
1321512 .1 92 1.160 GT
6600 1321463 Brown 10/51.7 1.174 12.0" 36· 21/39
.200
7000 1321463 RedlWhite 10/51.7 1.174 12.0" 36· 21/35
.1 92
8000 1321481 Blue 10M 1.174 12.0"
34·
19/35
47.5 Blue 47.5
7800 1321515 Silver 10M 1.1 74 12.0" 36· 19/35
1321515 .208 18/35
1321516 19/35
7800 1321516 RedlWhite 10 1.174 12.0" 36· 19/41
.192
7800 1321480 Gold 10 1.177 12.0" 34· 21/35
.207 51.7 19/35
1990 HIGH ELEVATION RECOMMENDATIONS
5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Clutch Driven Chaincase Shift Weight Clutch Spring Driven Chaincase
Spring Helix Gearing Helix Gearing
RedlWhite 36· ***** 08 RedlWhite 36·
••• **
15/39 15/39
Blue 36· .'***'*
06 Blue 36· *****
Gold 34·
17/35 10 or Blue or
34·
17/35
10M Blue Gold
RedlWhite 36· 21/39 10M Blue RedlWhite 36· 21/39
RedlWhite 36· 21/35 10M Red RedlWhite 36· 21/35
Blue 34·
19/35 10M Red Blue 34· 19/35
Blue 36· 19/35 10M Blue Blue 36· 19/35
18/35 18/35
RedlWhite 36· 19/41 10M White RedlWhite 36· 19/41
Blue
34·
21/35 10M White Blue 34·
21 /35
19/35 19/35
7.17
8/94
TORQUE-O-MATIC DRIVE
Data
Machine Engine Model Operating
Model RPM±200
StarLite EC25PS-07 6300
Indy Lite EC34-2PM-03 6500
Indy Sport, EC44-3PM-01 6800
GT
Indy Trail EC50PM-03 6600
Super Trak
Indy Trail '\ EC50PM-01/02 7000
(AU)
Indy 400 EC40PL-02l04 8000
Indy 500 EC50PL-01 /0204/05 7800
SKS/SP
Classic
WideTrak EC50PL-06 7000
650/RXL EC65PL-02l03 7800
RXLSKS
1991 PRODUCTION SETUP
Production Spring Color, Shift Wt. Bore Taper
Clutch Wire Dia. I.D.lGram Diameter
Part No.
1321514 Brown 08/47.5 1.174
.200
1321513 Brown 10/51.7 1.174
.200
1321507 RedlWhite 10/51.7 1.174
.192 1.160 GT
1321498 Brown 10/51 .7 1.174
.200
1321461 RedlWhite 10/51.7 1.174
.192
1321459 Blue 10M Bluel 1.174
.207 47.5
1321502 Silver 10M 1.174
1321502 .208
1321501
1321508 RedlWhite 10 1.174
.192
1321517 Gold 10AL 1.177
.207 53
1991 HIGH ELEVATION RECOMMENDATIONS
Clutch Driven
Center Helix
Di stance Angle
12.0" 36'
11 .5" 36'
11 .5" 36'
12.0" 36'
12.0" 36'
12.0" 34'
12.0" 36'
12.0" 36'
12.0" 36'
Machine 5000 Feet to 8000 Feet 8000 Feet to 12000 Feet
Model
Shift Weight Clutch Driven Chaincase Shift Weight Clutch Spring Driven
Spring Helix Gearing Heli x
StarLite 08 RedIWhite 36'
* ••••
08 RedIWhite 36'
15/39
Indy Lite 05 Blue 36'
.....
06 Blue 36'
Indy Sport, GT 10 Gold 36' 17/35 10 or Blue or 36'
10M Blue Gold
SuperTrak 10M Red/white 36' 21/39 10M Blue Red/white 36'
Indy Trail 10M Red/white 36' 21/35 10M Red Red/white 36'
(All)
Indy 400 10M Red Blue 34' 19/35 10M Red Blue 34'
Indy 500 10M Blue Blue 36' 19/35 10M Blue Blue 36'
500 SKS 18/35
WideTrak 10M Blue RedIWhite 36' 19/41 10M White Red/White 36'
650/RXL 10M Blue Blue 36' 21135 10M White Blue 36'
RXLSKS 19/35
8/94
7.18
..
Gearing
Chain
PitchfType
Direct
Drive
Direct
Drive
16/35
21/39
21/35
19/35
19/35
18/35
19/35
19/41
21/35
19/35
Chaincase
Gearing
* ••••
.* ...
17/35
21/39
21/35
19/35
19/35
18/35
19/41
21/35
19/35
1992 PRODUCTION SETUP
c
Spring
Operating Production Color,
Machine Engine RPM Clutch Wire Shift Wt.
Model Model ± 200 Part ~ o . Dia. I. D./G ram
Star Lite EC25PS-Q7 6300 1321514 Orange 10M Red
.196
Indy Lite EC34-2PM-0302 6500 1321513 Gold 10
Lite Deluxe
1321552 .207
Indy Lite GT EC34-2PM-04 7000 1321507 Red! 10MB
White
.192
Sport 440 EC44-3PM-01 6800 1321523 Brown 10
Sport 440 GT
.200
Trail EC50PM-01 7000 1321539 Red! 10
Trail Deluxe 102 1321540 White
.192
SuperTrak EC50PM-03 6600 1321541 Brown 10
.200
WideTrak EC50PL-06 7000 1321545 Brown 10
.200
440 Indy EC50PL-02 7800 1321547 Blue 10MB
Bushed
440XCR EC50PL-01 8000 1321547 Blue 10MB
Bushed
Indy 500 EC50PL-04 7800 1321543 Gold 10 M
Classic 105
1321544 Bushed
500 SP EFI EC50PL-07 7800 1321543 Gold 10 M
500 SKS
Bushed
Indy 650 EC65PL-02 8000 1321546 Blue 10 AL
Bushed
RXL EC65PL-03 8000 1321546 Blue 10AL
RXLSKS
Bushed
7.19
TORQUE-O-MATIC DRIVE
Data
. Driven
Bore Clutch Helix
Taper Center Angle & Chaincase
Dia. Distance Location Gearing
1.160 11 .50" 36° Direct Drive
B-2
5 Tooth
1.160 10.625" 36° Direct Drive
B-2
6 Tooth
1.160 11.03" 36° 16:39
B-2
1.160 12.00" 36° 16:35
B-2
16:39
1.174 12.00" 36° 21:39
#2
1.174 12.00" 36° 21:39
#2
1.174 12.00" 36° 19:41
#2
1.174 12.00" 34° 21 :39
#2
1.174 12.00" 36° 21:39
#2.
1.174 12.00" 36° 21:39
#2 20:39
1.174 12.00" 36° 21:39
#2 20:39
1.177 12.00" 36° 20:35
#2 .
1.177 12.00" 36° 20:35
#2 21:39
8/94
t '
TORQUE-O-MATIC DRIVE
Data
1992 HIGH ELEVATION RECOMMENDATIONS
\ " , , , , , , ! < ~ ..
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 Ft. 9000 Ft. to 12000 Ft.
Machine
Chain- Chain- Chain-
Model
Shift Clutch Driven case Shift Clutch Driven case Shift Clutch Driven case
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix Geari,ng
StarLite 10M Red! 36
e
D. Drive 10M Gold 36
e
D. Drive 10M Blue 36
e
D. Drive
Red White B-2
5 Tooth
Red B-2
5 Tooth
Red B-2
5 Tooth
Indy Lite 10 Blue 36
e
D. Drive 10M Gold 36
e
D. Drive 10M Blue 36
e
D. Drive
Deluxe B-2
6 Tooth
B-2
6 Tooth
B-2
6 Tooth
Indy Lite 10M Gold 36
e
16:39 10M Gold 36
e
16:39 10M Blue 36
e
16:39
GT
Blue B-2 White B-2 White or
or
B-2
10M Red
Gold
Sport 440 10 Red! 36
e
16:35 10 Gold 36
e
16:35 10 or Blue 36
e
16:35
Sport 440
White B-2
16:39
B-2
16:39 10M Blue
Gold B-2
16:39
GT
Trail 10 Red! 36
e
21:39 10M Red! 36
e
21:39 10M Red! 36
e
21:39
Trail White #2 White #2
Blue
White #2
Deluxe
SuperTrak 10 Red! 36
e
21:39 10M Red! 36
e
21:39 10M Red! 36· 21:39
White #2 White #2
Blue
White #2
WideTrak 10 Red! 36· 19:41 10M Red! 36· 19:41 10M Red! 36· 19:41
White #2 Blue White #2
White
White #2
440 Indy 10M Blue 34· 21:39 10M Blue 34
e
21:39 10M Blue 34· 21:39
White
#2
Red
#2
Red
#2
440 XCR 10M Blue 36· 21:39 10M Blue 34· 21:39 10M Red Blue 34· 21:39
White
#2
White
#2
Bushed
#2
Bushed Bushed
Indy 500 10M Gold 36· 21:39 10M Blue 36· 21:39 10M White Blue 36· 21 :39
Classic
Blue
#2
20:39 Blue
#2
20:39 Bushed
#2
20:39
Bushed Bushed or 10M Red
Bushed
500 SP EFI 10M Gold 36· 21:39 10M Blue 36· 21:39 10M White Blue 36· 21:39
500 SKS
Blue
#2
20:39 Blue
#2
20:39 Bushed
#2
20:39
Bushed Bushed or 10M Blue
Bushed
650/RXL 10 Blue 36· 20:35 10M Blue 36· 20:35 10M White Blue 36· 20:35
RXLSKS
Bushed #2
21:39 Blue #2 21:39 Bushed #2 21:39
Bushed
8/94
7.20
)
1993 PRODUCTION SETUP
Spring
Operating Production Color,
Machine Engine RPM Clutch Wire Shift wt.
Model Model ± 200 Part No. Dia. I.D.lGram
StarLite EC25PS-07 6300 1321514 Orange 10M Red
StarLite GT
.196
Indy LitelGT EC34-2PM-04 7000 1321560 SilverI 10
Lite Deluxe
1321561
Gold
.218
Sport EC44-3PM-01 6800 1321568 Brown 10
.200
Trail Deluxe EC44-3PM-01 6800 1321568 Brown 10
.200
Trail EC50PM-01 7000 1321570 Red! 10
White
Bushed
.192
WideTrak EC50PM-06 7000 1321567 Brown 10
.200 Bushed
440 Indy EC45PL-02 7800 1321580 Gold 10 MB
440 SKS
.207 Bushed
440 XCR EC45PL-01 8000 1321564 Blue 10 MB
.207 Bushed
Classic EC50PL-04 7800 1321569 Gold 10 M
Classic Touring
EC50PL-05 1321544 .207 Bushed
500 SP EFI EC50PL-07 7800 1321569 Gold 10 M
500 EFI SKS
.207 Bushed
XLTIXLT SP EC58PL-01 8000 1321571 Gold 10M
XLT SKS
.207 Bushed
RXL EC65PL-05 8000 1321546 Blue 10 AL
RXLSKS
.207 Bushed
Storm EC75PL-01 8000 1321581 Blue! 10-64
Storm SKS Gold
Bushed
.207
c
7.21
TORQUE-O-MATIC DRIVE
Data
Driven
Bore Clutch Helix
Taper Center Angle & Chaincase
Dia. Distance Location Gearing
1.160 12.236" 36S 15:41
B-2
1.160 11.030" 36S 16:39
B-2
1.160 12.00" 36° 16:35
B-2
1.160 12.00" 36S 16:39
B-2
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 19:41
#2
1.190 12.00" 34° 21 :39
#2 20:39
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 21:39
#2 20:39
1.190 12.00" 36° 21:39
#2 20:39
1.177 12.00" 34° 21:39
20:39
1.177 12.00" 36° 21:39
#2 20:39
1.177 12.50" 34° 23:37
8/94
TORQUE-O-MATIC DRIVE
Data
1993 HIGH ELEVATION RECOMMENDATIONS
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 Ft. 9000 Ft. to 12000 Ft.
Machine
Chain- Chain-
Model
Shift Clutch Driven case Shift Clutch Dri ven case Shift Clutch Driven
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix
StarLite 10M Red! 36.5° 15:41 10M Gold 36.5° 15:41 10M Blue 36S
StarLite GT
Red White B-2 Red B-2 Red B-2
Lite GT 10M Gold 36.5° 16:39 10M Gold 36.5° 16:39 10M White Blue 36.5°
Lite
Blue B-2 White B-2
or 10M Red
Gold B-2
Lite Deluxe
Sport 10 Red! 36° 16:35 10 Gold 36° 16:35 10 or Blue 36°
White B-2 B-2
10M Blue
Gold B-2
Trail Deluxe 10 Red! 36.5° 16:39 10 Gold 36° 16:39 10 or Blue 36.5°
White B-2 B-2
10M Blue
Gold B-2
Trail 10 Red! 36° 21:39 10M Red! 36° 21 :39 10M Redl 36°
Bushed White #2 Bushed White #2
Blue
White #2
WideTrak 10 Red! 36° 19:41 10M Red! 36° 19:41 10M Red! 36°
Bushed White #2
Blue
White #2
White
White #2
Bushed
440 Indy 10M Blue 34° 21:39 10M Blue 34° 21:39 10M Bl ue 34°
White
#2
Red
#2
Red
#2
Bushed Bushed Bushed
440SKS 10M Blue 34° 20:39 10M Blue 34° 20:39 10M Blue 34°
White
#2
Red
#2
Red
#2
Bushed Bushed Bushed
440 XCR 10M Blue 34° 21:39 10M Blue 34° 21 :39 10M Red Blue 34°
White
#2
White
#2
Bushed
#2
Bushed Bushed
Classic 10M Gold 36° 21:39 10M Blue 36° 21:39 10M White Blue 36°
Blue
#2
Blue
#2
or 10M Red
#2
Bushed Bushed
Classic 10M Gold 36° 20:39 10M Blue 36° 20:39 10M White Blue 36°
Touring Blue
#2
Blue
#3
or 10M Red
#3
Bushed Bushed
500 EFI 10M Gold 36° 21 :39 10M Blue 36° 21:39 10M White Blue 36°
Blue
#2
Blue
#3
or 10M Blue
#3
Bushed Bushed
500 EFI SKS 10M Gold 36° 20:39 10M Blue 36° 20:39 10M White Blue 36°
Blue
#2
Blue
#3
or 10M Blue
#3
Bushed Bushed
XLT/XLT SP 10M Gold 34° 21:39 10M Blue 34° 21:39 10M Red Blue 34°
Blue White Bushed
Bushed
Bushed
XLT SKS 10M Gold 34° 20:39 10M Blue 34° 20:39 10M Red Blue 34°
Blue White Bushed
Bushed
Bushed
RXL 10 Blue 36° 20:35 10M Bl ue 34°#2 20:35 10M White Blue 36°
Bushed #2
Blue or36° Bushed 2#
Bushed #3
RXL SKS 10 Blue 36° 21:39 10M Blue 34°#2 21:39 10M White Blue 36°
Bushed #2
Blue or 36° Bushed #2
Bushed #3
Storm 10-60 SilverI 34° 23:37 10A SilverI 34° 23:37 10 SilverI 34°
Storm SKS Bushed Gold #2 Bushed Gold Bushed Gold
8/94
7.22
Chain-
case
Gearing
15:41
16:39
16:35
16:39
21:39
19:41
)
21:39
20:39
21:39
21:39
20:39
21:39
20:39
21:39
20:39
20:35
21:39
21:37
1994 PRODUCTION SETUP
Machine Engine Operating Production Spring Shift Wt.
Model Model RPM ± Clutch Color, I.D.lGram
200 Part No. Wire
Dia.
Star Lite EC25PS-Q7 6300 1321599 Orange 10M Red
Star Lite GT
.196
Indy Lite/GT EC34-2PM-04 7000 1321601 SilverI 10
Lite Deluxe -02
1321602
Gold
.218
Sport EC44-3PM-01 6800 1321594 Brown
10 \
Sport SKS
1321619 .200
Super Sport
Trail Deluxe EC50PM-02 6800 1321592 Brown 10
.200
Trail EC50PM-01 7000 1321570 Red! 10
White
Bushed
.1 92
WideTrak GT EC50PM-03 7000 1321583 Brown 10
WideTrak LX
EC50PL-06 .200 Bushed
440 Indy EC45PL-02 7800 1321580 Gold 10MB
440 SKS
.207 Bushed
440 XCR EC45PL-01 8000 1321564 Blue 10MB
.207 Bushed
Classic EC50PL-05 7800 1321606 Gold 10M
Classic
EC50PL-08 .207 Bushed
Touring
500 SP EFI .. EC50PL-07 7800 1321569 Gold 10 M
500 EFI SKS
.207 Bushed
XLTIXLT SP ( EC58PL-01 8000 1321571 Gold 10 M
XLT SKS
.207 Bushed
RXL EC65PL-05 8000 1321608 Blue 10AL
RXL Touring
EC65PL-06 .207 Bushed
Storm EC80PL-01 8000 1321ro7 Blue 10-62
Storm SKS
G:J?> .207 Bushed
7.23
TORQUE-O-MATIC DRIVE
Data
Bore Clutch Driven Chaincase
Taper Center Helix Gearing
Diamet Distance Angle &
er Location
1.160 12.24" 36S 15:41
B-2
1.160 11.030" 36.5° 16:39
B-2
-
1"\
1.160 V 12.00" 36° 16:35
~
B-2
1.160 12.00" 36S 16:39
B-2
1.190 12.00" 36° 21:39
.....----
#2
1.190 12.00" 36° 19:41
#2
1.190 12.00" 34° 21:39
#2 20:39
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 21:39
#2 20:39
1.190 12.00" 36° 21:39
#2 20:39
1.174 12.00" 34° 21:39
20:39
1.177
12.00\
36° 21:39
#2 20:39
1.177 12.50" 42-36-34° 23:37
Combina-
21:37
tion
8/94
TORQUE-O-MATIC DRIVE
Data
1994 HIGH ELEVATION RECOMMENDATIONS
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 Ft. 9000 Ft. to 12000 Ft.
Machine
Chain- Chain-
Model
Shift Clutch Driven case Shift Clutch Driven case Shift Clutch Driven
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix
StarLite 10M Red! 36.5° 15:41 10M Gold 36.5" 15:41 10M Blue 36.5"
StarLite GT
Red White #B-2 Red #B-2 Red #B-2
Lite GT 10M Gold 36.5° 16:39 10M Gold 36.5° 16:39 10M White Blue 36.5°
Lite
Blue #B-2 White #B-2
or 10M Red
Gold #B-2
Lite Deluxe
Sport 10 Red! 36° 16:35 10 Gold 36° 16:35 10 or Blue 36°
White #B-2 #B-2
10M Blue
Gold #B-2
Sport SKS 10 Red! 36° 16:39 10 Gold 36° 16:39 10 or Blue 36°
White #B-2 #B-2
10M Blue
Gold #B-2
Super Sport 10AL Red 36° 17:35 10AL Gold 36° 17:35 10 or Red! 36°
Bushed
#B-2
Bushed
#2
10M Blue White
#B-2
Bushed
Gold
Trail Deluxe 10 Red! 36° 22:41 10M Red! 36° 22:41 10M Blue Red! 36°
Bushed
White #2
Bushed White
#2
Bushed White
#2
Trail 10 Red! 36° 21 :39 10M Red! 36° 21:39 10M Red! 36°
Bushed White #2 Bushed White #2
Blue
White #2
Bushed
WideTrakLX 10 Red! 36° 19:41 10M Red! 36° 19:41 10M Red! 36°
Bushed White #2
Blue
White #2
White
White #2
Bushed Bushed
WideTrak 10 Red! 36° 19:41 10M Red! 36° 19:41 10M Red! . 36°
GT
Bushed White #2 Bushed White #2
Blue
White #2
Bushed
440 Indy 10M Blue 34° 21:39 10M Blue 34° 21 :39 10M Blue 34°
White
#2
Red
#2
Red
#2
Bushed Bushed Bushed
440 SKS 10M Blue 34° 20:39 10M Blue 34° 20:39 10M Blue 34°
White
#2
Red
#2
Red
#2
Bushed Bushed Bushed
440 XCR 10M Blue 34° 21:39 10M Blue 34° 21 :39 10M Red Blue 34°
White
#2
White
#2
Bushed
#2
Bushed Bushed
Classic 10M Gold 36° 21:39 10M Blue 36° 21:39 10M White Blue 36°
Blue
#2
Blue
#2
Bushed
#2
Bushed Bushed or 10M Red
Bushed
Classic 10M Gold 36° 20:39 10M Blue 36° 20:39 10M White Blue 36°
Touring Blue
#2
Blue
#3
Bushed
#3
Bushed Bushed or 10M Red
Bushed
500 EFI 10M Gold 36° 21:39 10M Blue 36° 21 :39 10M White Blue 36°
Blue
#2
Blue
#3
Bushed
#3
Bushed Bushed or 10M Blue
Bushed
500 EFI 10M Gold 36° 20:39 10M Blue 36° 20:39 10M White Blue 36°
SKS Blue
#2
Blue
#3
Bushed
#3
Bushed Bushed or 10M Blue
Bushed
XLTIXLT SP 10M Gold 34° 21:39 10M Blue 34° 21:39 10M Red Blue 34°
Blue White Bushed
Bushed ,
Bushed
XLT SKS 10M Gold 34° 20:39 10M Blue 34° 20:39 10M Red Blue 34°
Blue White Bushed
Bushed
Bushed
RXL 10 Blue 36° 20:35 10M Blue 34°#2 20:35 10M White Blue 34°#2
Bushed #2
Blue or 36° Bushed or 36°
Bushed #3 #3
RXL Touring 10 Blue 36° 21:39 10M Blue 34°#2 21:39 10M White Blue 34°#2
Bushed #2
Blue or36° Bushed or 36°
Bushed #3 #3
Storm 10-60 Blue Stock 23-37 10-58 Blue Stock 23-37 10 Bushed or Blue Stock
Bushed Bushed 10ALBushed
Storm SKS 21-37 21 -37
8/94
7.24
Chain-
case
Gearing
15:41
16:39
16:35
16:39
17:35
22:41
21:39
19:41
19:41
21:39
20:39
21:39
21:39
20:39
21 :39
20:39
21:39
20:39
20:35
21:39
23-37
21-37
1995 PRODUCTION SETUP
Machine Engine Operating Production Spring Shift WI.
Model Model RPM ± Clutch Color, I.D.!Gram
200 Part No. Wire
Dia.
StarLite EC25PS07 6300 1321599 Orange 10M Red
.196
Indy LitelGT EC34-2PM02 7000 1321601 SilverI 10
Lite Deluxe 1321602 Gold
.218
Sport EC44-3PM01 6800 1321594 Brown 10
Sport Touring .200
Super Sport EC44-3PM02 7000 1321619 Red! 10AL
White Bushed
.1 92
l
Trail EC50PM04 7000 1321570 Red! 10AL
White Bushed
.192
Trail Deluxe EC50PME04 7000 1321592 Red! 10AL
White Bushed
.192
WideTrak GT . EC50PM03 6600 1321583 Brown 10
.200 Bushed
WideTrak LX EC50PL06 7000 1321583 Brown 10
.200 Bushed
440 Indy EC45PL02 8000 1321580 Gold 10MB
.207 Bushed
440 SKS
440 XCR EC45PL05 8250 1321643 Blue 10MB
.207 Bushed
Indy 500 EC50PL04 7750 1321569 Gold 10MB
.207 Bushed
Classic EC50PLE04 7750 1321606 Gold 10M
.207 Bushed
500 EFI EC50PL07 8000 1321569 Gold 10M
.207 Bushed
500 EFI SKS
XLT/XLT SP EC58PL03 8000 1321571 Gold 10M
.207 Bushed
XLT SKS
XLT Touring EC58PLE04 8250 1321642 Gold 10M
.207 Bushed
600 XCR EC58PL02 8500 1321626 Blue 10MB
, .207 Bushed
RXL EC65PL05 8000 1321620 Blue 10 AL
.207 Bushed
RXL Touring EC65PLE05 1321608
Storm EC80PL01 8250 13216.07 Blue 10-62
Storm SKS , , ; . ~ .207 Bushed
7.25
TORQUE-O-MATIC DRIVE
Data
Bore Clutch Driven Chaincase
Taper Center Helix Gearing
Diamet Distance Angle &
er Location
1.160 12.24" 36S 15:41
B-2
1.160 11.030" 36S 16:39
B-2
1.160 12.00" 36.5° 16:35
B-2 16:39
1.160 12.00" 36S 17:35
B-2
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 20:39
#2
1.190 12.00" 36° 19:41
#2
1.190 12.00" 36° 19:41
#2
1.190 12.00" 34° ·21:39
#2
20:39
1.190 12.00" 34° 21:39
#2
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 21:39
#2
1.190 12.00" 36° 21:39
#2
20:39
1.177 12.00" 34° 21:39
#2
20:39
1.177 12.00" 34° 20:39
#2
1.177 12.00" 34° 21:39
#2
1.177 12.00" 36° 20:35
#2 21:39
1.177 12.50" 34° 23:37
#2 20:35
-
8/94
TORQUE-O-MATIC DRIVE
Data
1995 HIGH ELEVATION RECOMMENDATIONS
3000 Ft. to 6000 Ft. 6000 Ft. to 9000 Ft. 9000 Ft. to 12000 Ft.
Machine
Chain- Chain-
Model
Shift Clutch Driven case Shift Clutch Driven case Shift Clutch Driven
Weight Spring Helix Gearing Weight Spring Helix Gearing Weight Spring Helix
StarLite 10M Red! 36.5° 15:41 10M Gold 36.5° 15:41 10M Blue 36S
Red White #B-2 Red #B-2 Red #B-2
Lite GT 10M Gold 36S 16:39 10M Gold 36S 16:39 10M White Blue 36.5°
Lite
Blue #B-2 White #B-2
or 10M Red
Gold #B-2
Lite Deluxe
Sport 10 Red! 36.5° 16:35 10 Gold 36S 16:35 10 or Blue 36.5°
White #B-2 #B-2 10M Blue Gold #B-2
Sport 16:39 16:39
Touring
Super Sport 10 Red! 36S 17:35 10AL Gold 36S 17:35 10M Blue Red! 36S
Bushed White #B-2 Bushed #B-2 Bushed or White #B-2
10 Bushed Gold
Trail 10AL Red! 36° 21:39 10 Red! 36° 21:39 10M Blue Red! 36°
Bushed White #2 Bushed White #2
Bushed
White #2
Trail Deluxe 20:39 20:39
WideTrak LX 10 Red! 36° 19:41 10M Red! 36° 19:41 10M Red! 36°
Bushed White #2
Blue
White #2
White
White #2
Bushed Bushed
WideTrak 10 Red! 36° 19:41 10M Red! 36° 19:41 10M Red/ 36°
GT
Bushed White #2 Bushed White #2
Blue
White #2
Bushed
440 Indy 10M Blue 34° 21:39 10M Blue 34° 21:39 10M Blue 34°
White
#2
Red
#2
Red
#2
Bushed Bushed Bushed
440 SKS 20:39 20:39
440XCR 10M Blue 34° 21 :39 10M Blue 34° 21:39 10M Red Blue 34°
White
#2
White
#2
Bushed
#2
Bushed Bushed
600XCR 10MW Blue 34° 21 :39 10MR Blue 34° 21:39 10MR Blue 34°
Bushed #2 Bushed #2 Bushed #2
Indy 500 10M Gold 36° 21:39 10M Blue 36° 21:39 10M White Blue 36°
Blue
#2
Blue
#2
Bushed or
#2
Bushed Bushed 10M Red
Bushed
Classic 10M Gold 36° 21:39 10M Blue 36° 21:39 10M White Blue 36°
500 EFI Blue
#2
Blue
#2
Bushed
#2
Bushed Bushed or 10M Red
Bushed
500 EFI SKS 10M Gold 36° 20:39 10M Blue 36° 20:39 10M White Blue 36°
Blue
#2
Blue
#3
Bushed
#3
Bushed Bushed or 10M Red
Bushed
XLTIXLT SP 10M Gold 34° 21:39 10M Blue 34° 21:39 10M Red Blue 34°
Blue
#2
White
#2
Bushed
#2
Bushed Bushed
XLT SKS 20:39 20:39
XLT Touring 10M Gold 34° 20:39 10M Blue 34° 20:39 10MRed Blue 34°
Blue
#2
White
#2
Bushed
#2
Bushed Bushed
RXL 10 Blue 36° 20:35 10M Blue 34°#2 20:35 10M White Blue 34°#2
Bushed #2
Blue or 36° Bushed or 36°
Bushed #3 #3
RXL Touring 10 Blue 36° 21:39 10M Blue 34°#2 21:39 10M White Blue 34°#2
Bushed #2
Blue or 36° Bushed or 36°
Bushed #3 #3
Storm 10-60 Blue 34° 23:37 10-58 Blue 34° 23:37 10 Bushed or Blue 34°
Bushed #2 Bushed #2 10ALBushed #2
Storm SKS 20:35 20:35
8/94
7.26
Chain-
case
Gearing
15:41
16:39
16:35
16:39
17:35
21:39
20:39
19:41
19:41
21 :39
20:39
21:39
21 :39
21:39
21:39
20:39
21:39
20:39
20:39
20:35
21:39
23:37
20:35
c
)
TORQUE-O-MATIC DRIVE
Drive Clutch Service Parts

___________ 9._8_. _____________
y
1.
IRetl Part No. I Qty·1 Description I Ref I Part No I Qty·1 Description
1. ** 1 Asm., Drive Clutch Basic
2. 7512265 6 Bolt
3. 7552801 6 Washer, Spri ng Lock
4. 3576510 1 Cover, Bearing
5. 7710417 1 Ring, Retaining, Cover
6. ** 1 Spring, Clutch
12. 1321457 3 Asm., Roller & Bushing
1321622 3 Asm. , Roller & Bushing
(Storm Only)
13. 5430768 3 Button, Guide
14. 5210754 AR Spacer, .050mm
5210753 AR Spacer, .032mm
5210752 AR Spacer, .020mm
7. 5020436 3 Pin, Roller
5020422* 3 Pin, Roller
15. ** 3 WeighUBushing
16. 7541906 3 Nut
8. 5410374 3 Seal
17. 7512266 3 Bolt
9. 5430728 3 Button, Guide
5430728 Button, Guide
10. 5020425 1 Nut, Jam
18. 3576502 1 Bearing, Sleeve
3576503 1 Bearing, Sleeve (Trail
w/EC50PM)
11 . 5430945 6 Washer, Multilube
19. 5010188 1 Insert, Moveable
• All other P-85 BasIc except 500 90/91
2. 3.
5.

12.-&) ,/
, \
\ ' ,
V , -'

y
1.
IRetl Part No. I Qty· 1 Description I Ref I Part No I Qty·1 Description
1. 1321523 1 Asm.,Drive Clutch Basic
2. 7512265 6 Bolt
3. 7552804 6 Washer, Split Lock (6mm)
4. 3576510 1 Cover, Bearing
5. 7041061 1 Spring, Clutch (Brown)
6. 5020422 3 Pin, Roller
7. 5430728 6 Button, Guide
10. 5210754 AR Spacer, .050mm
5210753 AR Spacer, .032mm
5210752 AR Spacer, .020mm
11. 3576504 1 Bearing, Moveable 1/2"
12. 5630272 2 Shift, Weight (10)
13. 7512266 3 Bolt, Shoulder
14. 7541906 3 Nut, Flex Lac
8. 5430945 6 Washer, Multil ube
9. 1321457 3 Asm., Roller and Bushing
7.27
8/94
I'
TORQUE-O-MATIC DRIVE
Drive Clutch Weight Identification - Actual Size
u y W
Gram Weight: 34 ± 1 Gram Weight: 35 ± 1 Gram Weight: 37.5 ± 1
PN 5630107 PN 5630139 PN 5630109
B
A
8 A
Gram Weight: 43 ± 1 Gram Weight: 47.5 ± 1
PN 5630084 PN 5630080
02
02
Gram Weight: 49 ± 1
PN 5630225
8/94
o
Gram Weight: 51
PN 5610088
AlP
Gram Weight: 47.5± 1
PN 5630094
o
Gram,Weight: 53 ± 1
PN 5630174
7.28
G - (8 Modified)
Gram Weight: 41 .5 ± 1
PN 5630063
01
01
Gram Weight: 48.5 ± 1
PN 5630224
03
03
Gram Weight: 32.5 ± 1
PN 5630227
o
o
TORQUE-O-MATIC DRIVE
Drive Clutch Weight Identification - Actual Size
04
04
Gram Weight: 57.5 ± 1
PN 5630229
P1
Gram Weight: 42 ± 1
PN 5630089
07
M1 (Modified)
Gram Weight: 46.0 ± 1
PN 5630301
J1
Gram Weight: 44 ± 1
PN 5630065
08
N1 (Modifi ed)
Gram Weight: 51.5 ± 1
PN 5630302
05
Gram Weight: 53.5 ± 1
PN 5630234
07 08 09
K1
Gram Weight: 39 ± 1
PN 5630144
06
Gram Weight: 50 ± 1
PN 5630243
10
Gram Weight: 52 ± 1 Gram Weight: 47.5 ± 1 Gram Weight: 51 .5 ± 1
PN 5630244 PN 5630245 PN 5630249
Gram Weight: 51 .5± 1
PN 5630272
7.29 8/94
-
TORQUE-O-MATIC DRIVE
Drive Clutch Weight Identification - Actual Size
15 10A
Gram Weight: 55.5 ± 1 Gram Weight: 55.0 ± 1
PN 5630274 PN 5630286
10M Red
Gram Weight: 44 ± 1
PN 5630325
10M-W Bushed
Gram Weight: 46 ± 1
PN 1321527
·8/94
10MIW
Gram Weight: 46 ± 1
PN 5630369
10M
10M Bushed
Gram Weight: 49.5 ± 1
PN 1321528
10M
Gram Weight: 49.5 ± 1
PN 5630273
10AlL
Gram Weight: 53 ± 1
PN 5630368
10M
B
10M Blue Bushed
Gram Weight: 47.5± 1
PN 1321529
7.30
10M Blue
Gram Weight: 47.5 ± 1
PN 5630324
10 Bushed
Gram Weight: 51.5 ± 1
PN 1321526
1 OM Red Bushed
Gram Weight: 44 ± 1
PN 1321530
1 O-AL Bushed
Gram Weight: 53 ± 1
PN 1321531
1 0-60 Bushed
Gram Weight: 60
PN 1321587
TORQUE-O-MATIC DRIVE
Drive Clutch Weight Identification - Actual Size
1 0-66 Bushed
Gram Weight: 66
PN 1321584
1 0-64 Bushed
Gram Weight: 64
PN 1321585
1 0-62 Bushed
Gram Weight: 62
PN 1321586
10-58 Bushed ;
Gram Weight: 58
PN 1321588
7.31
10A Bushed
Gram Weight: 55
PN 1321589
8/94
r TORQUE-O-MATIC DRIVE
Drive Clutch Spring Rates
The followi ng chart will aid in the setup and balance of engine RPM power curves for special converter tuning
requirements such high operating altitude, heavy loads, mountainous terrain, etc.
DRIVE CLUTCH SPRING COMPRESSION RATE CHART
300 --,....- ,
!... 1
"\--_ ..-
!
...__--- Blue/Blue-Gold
7041080
280 : ...
260 -f----,.-

I
I
240 -;
P-90 TRAVEL

, .
I
I
220 +·---i----'
I ! .
200
-1 1
; !

?
;
en
c
z ;
160 -1
......... t
w
o
a:
o
u..
8/94

COMPRESSED SPRING LENGTH (INCHES)
7.32
_ Silver/Gold
7041286
, =.
PART NUMBER COLOR CODE
7041021 Clear
7041022 Black
7041063 Purple
7041062 Silver
7041065 Pink
7041060 Orange
7041080 Blue/Gold
7041083 Red
7041102 Yellow
7041061 Brown
7041132 White
7041168 Green
7041148 Gold
7041150 Red/White
7041286 Silver/Gold
,
TORQUE-O-MATIC DRIVE
Drive Clutch Spring Data
WIRE DIAMETER FREE LENGTH +/- .1 25"
.157" 4.38"
.140" 4.25"
.168" 4.37"
.208" 3. 12"
.177" 4.69"
.196" 3.37"
.207" 3.50"
.192" 3.77"
.192" 2.92"
.200" 3.06"
.1 77" 2.92"
.177" 3.05"
.207" 3.25"
.192" 3.59"
.21 8" 3.05"
CAUTION: Never shim a drive clutch spring to increase its compression rate. This may result in complete stack-
ing of the coils and subsequent clutch cover failure.
Maximum efficiency of the variable speed drive system is dependent upon many factors. Included in these are
converter alignment, belt tension, and internal conditi on of the drive and dri ven clutch components. One of the
most critical and easily serviced parts is the drive clutch spring. Due to the severe stress the spring is subject
to during operation, it should always be inspected and checked for tolerance limits during any clutch operation
diagnosis or repair.
With the spring resting on a flat surface, measure its
free length from its outer coil surfaces as shown. Refer
to the chart above for specific free length measure-
ments and tolerances.
In addition to proper free length, the spring coils should
be parallel to one another when placed on a fl at sur-
face. Distortion of the spring indicates stress fati gue.
Replacement is required.
7.33
8/94
TORQUE-O-MATIC DRIVE
Drive Belt Adjustments
The drive belt is an important component of the converter
system. Critical dimensions and construction have been pro-
vided for at the time of manufacture. In order to achieve max-
imum efficiency from the converter, the drive belt must be ad-
justed properly for tension and clutch offset.
If the belt is too long or the center distance too short, the initial
starting ratio will be too low, resulting in performance loss.
This is due to the belt rising too high in the drive clutch
sheaves upon engagement.
If the drive belt is too short or the center distance too long,
the ratio will again be incorrect. In addition, the machine may
creep when the engine idles, causing damage to the internal
face of the drive belt.
8/94
7.34
o
c
Aluminum Driven Clutch
TORQUE-O-MATIC DRIVE
Drive Belt Adjustments
Ideal belt deflection is 1 1/4/1 (3.2 cm). Measure belt deflection with both clutches at rest and in their full neutral
position. Place a straight edge on the belt and apply downward pressure while measuring at the point shown.
To change belt deflection, add or delete thrust washers. NOTE: One thrust washer shoul d always be left between
the driven clutch sheaves.
Straight Edge
1 1/4/1 (3.2 cm)
IMPORTANT NOTE: Do not apply excessive pressure to force the belt into the driven sheaves. this will result
in an improper measurement.
Aluminum Driven Clutch with Outer Cam Adjuster
Belt deflection can be adjusted without removing the clutch from the jackshaft.
C 1. Pull belt into driven clutch to slightly open sheaves.
2. Loosen three bolts on adjustment cam.
3. Turn cam counterclockwise to reduce distance between sheaves.
4. Torque bolts to 10ft. Ibs. (1 .38 kg/m).
May use optional, thinner (.048/1) washer PN 7555899
7.35
8/94
TORQUE-O-MATIC DRIVE
Clutch Alignment
Clutch Alignment Tools:
PN 2870426 P8S Clutches, 5/8" Offset
PN 2870914 P90 Clutches, 21/32" Offset
Use the proper clutch alignment tool to check clutch offset.
When the clutches are properly aligned, the tool will con-
tact all sheave surfaces equally. The motor mounts on
some models are slotted to allow for installation of wash-
ers behind the driven clutch to achieve correct offset.
NOTE: The drive belt must be removed for this measure-
ment.
8/94
7.36
.. '
'. '
'..I, ',
21/32" Offset
All models with P90
aluminum driven clutch
5/8" Offset
All models with P8S
aluminum driven clutch
NOTE: Up to 1/8" air gap
allowed on new machines
Offset Alignment Tool
)
2.
o
IRef.1 Part No.
1. 1321551
2. 7512265
3. 7552801
4. 3576510
5. 7710417
6. 7041080
7. 5020422
8. 2200387
9. 5430445
10. 5430945
11. 1321457
1321622
TORQUE-O-MATIC DRIVE
P-85 Drive Clutch
12. 1N
L
9. II
! ~ ]
~ ~
i.--
' - ~ r
15.
~
16.
1.
I Qty·1 Description I Ref.1 Part No. I Qty·1 Description
1 Asm., Drive Clutch Basic 34 12. 5020425 1 Nut, Jam
(Less 6 & 14)
6 Bolt
6 Washer, Spring Lock
1 Cover, Bearing .
1 Ring, Retaining,Cover
1 Spring, Clutch (Blue)
3 Pin, Roller
1 Kit - Shim, Drive Clutch
6 Button, Guide
6 Washer, Multilube
3 Asm., Roller & Bushing
3 Asm., Roller & Bushing
(Storm Only)
13. 5210754 AR Spacer, .050mm
5210753 AR Spacer, .032mm
5210752 AR Spacer, .020mm
14. 1321531 3 Asm., Weight/Bushing
(10A-L)
15. 7515105 3 Pin, Weight
16. 7541906 3 Nut
17. 3576502 1 Bearing, Sleeve
3576503 1 Bearing, Sleeve (Trail
w/EC50PM)
18. 5010188 1 Insert, Moveable
7.37
8/94
TORQUE-O-MATIC DRIVE
Drive Clutch Identification and Removal
1. Install strap wrench PN 2870336 to clutch cover.
Remove drive cl utch retaining bolt and install
puller PN 2870506 into clutch. Tighten puller with
a wrench, or strike t-bar with a hammer until
clutch is removed.
2. Prior to reinstalling drive clutch to engine, bore
taper should be trued by usi ng tapered reamer PN
2870576. Place reamer in a vise and lubricate
with cutting oil. Clean taper by manually rotating
clutch clockwise.
3. Position clutch on engine crankshaft. Install
retaining bushing and bolt using strap wrench PN
2870336 to hold clutch. Torque retaining bolt to
40-45 ft. Ibs. CAUTION: Never use an air impact
wrench for installing or removing a drive clutch. It
will loosen the spider torque value and could
cause engine crankshaft damage.
While all drive clutches may look alike, each bears a
different number. This number indicates internal
clutch component variation for individual engines. For
easy identification, refer to the three numbers behind
date code on moveable sheave. These numbers are
the last three digits of that clutch part number .
. - - ~ - -
---
Used up to 1993
8/94
J
7.38
c
1. Carefully remove cover attachi ng screws.
Remember that there is spring tension on the cover.
2. Install drive clutch into clutch holding fixture PN
2870461.
3. On models equipped with a spider jam nut, install jam
nut tool PN 2870338 and remove jam nut.
4. Install spider removal tool PN 2870341 and remove
spider.
5. Count the number of spacer washers installed
beneath the spider.
TORQUE-O-MATIC DRIVE
Drive Clutch Disassembly and Inspection
7.39
8/94
TORQUE-O-MATIC DRIVE
Drive Clutch Disassembly and Inspection
10. Using a 1/8" Allen wrench and 3/8" combination
wrench, remove drive clutch fly weights.
11. Remove spider buttons using button removal tool
PN 2870985.
12. Place spider on a vise. USing a pin punch, drive
out the roller pin.
13. Inspect all rollers, bushings, thrust washers, and
roller pins.
8/94
7.40
c
C
1. Start a replacement roller on each leg, driving a pin in
about .100"-.125" (.25-.32 cm) beyond the fi rst land
of the spider leg (A) . TIP: This enables you to locate
the first washer and align the roller until the pin is flush
with the second land.
2. Install one washer onto the pin.
3. Place a few drops of Polaris clutch and cable lube
(PN 287051 0) onto the roller bushing. Place roller on
pin as it protrudes from first land.
4. Place a second washer on the other side of the roller.
5. I nstall service tool as shown in photo 2.
6. Place spider on a vise anvil and drive the roller pin
through to the second land of the spider. CAUTION:
Use care to start the pin straight. Aluminum burrs
could pass through into the roller bushing causing it to
bind and stick. Also use care to make sure the roller
remains aligned when the pin is driven through. The
roller bushing could be damaged causing premature
wear and roller failure.
7. Determine how many shims are to be used. NOTE:
Shim Kit PN 2200387 contains an assortment of
shims, including .002", .005", and .010".
8. Measure the dimension between towers at the lower
half of the towers as shown.
9. Install spider buttons using a soft face hammer.
7.41
TORQUE-O-MATIC DRIVE
Spider Assembly
8/94
TORQUE-O-MATIC DRIVE
Spider Assembly
10. Record width of spider buttons on each leg.
11. Add shims beneath spider button to obtain .002" (.05
mm) clearance between button and tower when
assembled.
12. Place the correct number of spacer washers
beneath the spider.
13. Assemble clutch making sure "X" marks are aligned
to achieve proper balance.
8/94
7.42
c
c
27. Torque spider to 200 ft. Ibs. (27.6 kg/m) . (Applies to
either P8S or P90 models.)
28. Torque jam nut to 235 ft. Ibs. (32.43 kg/m). (Select
P8S rifodels only.)
29. Install spring and cover. Torque cover screws to 90
inch Ibs.
7.43
""
TORQUE-O-MATIC DRIVE
SpiCIer. Assembly
8/94
TORQUE-O-MATIC DRIVE
Spider Indexing
1. Remove drive clutch from engine and remove drive
clutch cover and spring.
2. Mark spider, cover, moveable sheave, and
stationary sheave in line as shown in photo 1.
Fine Tuning
The distance between the belt and the moveable sheave
on the drive clutch is very important. This distance
controls the starting ratio (lowest starting ratio is most
preferable) and the position of the clutch weight to en-
gine RPM. The distance between the belt and moveable
sheave should be as close to .020" (.5 mm) as possible
without creating a drag on the belt when positioned
around the hub at the bottom of the sheaves.
New belt measurement width specification is 1.375" +/-
.032.
1. Measure total belt to sheave clearance with a feeler
gauge as shown in photo 2. NOTE: Any clearance
over .020" requires disassembly and re-shimming of
the spider.
Spider Shimming
1. Place drive clutch on holding fixture and unscrew
spider.
2. Adjust spider washer pack to achieve desired belt to
sheave clearance as described above.
The following washers are available for fine tuning:
PN 5210754 .050"
PN 5210753 .032"
PN 5210752 .020"
8/94 7.44
c
<[
3. Install spider washer(s) and spider. The spider must
be rotated clockwise into the moveable sheave to
maintain relative clutch balance after reassembly.
Re-indexing the spider 1/3 turn clockwise, or 1 leg, will .
allow the realignment of the moveable and stationary
sheaves as preViously marked. For example: ".
• .020" or .032" washer removed - re-index
spider clockwise 1/3 turn
• .050" or .064" washer removed - re-index
spider clockwise 1/3 turn
• Two .050" or .064" washers removed -
re-index clockwise 2/3 turn
NOTE: Alignment marks should be withi n 1" (2.5 cm) af-
ter final assembly and torquing.
7.45
TORQUE-O-MATIC DRIVE
Spider Indexing
8/94
. ..
TORQUE-Q-MATIC DRIVE
Aluminum Driven Clutch Service - P85
1. Remove snap ring and washer.
2. Inspect ramp buttons and bushing for wear.
3. Note condition of moveable sheave bushing. Install
helix into bushing. It should slide freely without
binding.
4. Polish helix with a fine emery cloth to remove any
sharp edges which may cause sticking.
5. Clean all parts.
6. Reassemble stationary and moveable sheaves. Note
the placement of the two thrust washers shown.
These washers may be used to adjust the effective
belt tension measurements as described earlier.
Removal of a thrust washer increa:ses neutral belt
tension. NOTE: Addition or subtraction of these
washers affects clutch alignment.
7. When driven offset is properly adjusted, the washers
(A) (PN 7555734) are used to adjust for free float on
drive. Without a slight free float, the jackshaft
bearings could be side loaded, causing premature
bearing failure. Torque bolt to 12 ft. Ibs. (1 .66 kg/m).
8/94
7.46
c
o
Helix Angles And Effects
TORQUE-O-MATIC DRIVE
Aluminum Driven Clutch Service - P-85
The driven clutch helix was selected for overall performance in relation to the other driven system components. In
fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift, we
recommend trying a helix change before changing other components.
Polaris has several helix angles available for the aluminum drive clutch. Refer to the chart below for specific angle
effects and identification.
Helix RPM Effect Identification
34° PN 5630168 Increasing Number 34 marked on back side of helix
36° PN 5630185 Decreasing Number 36 marked on back side of helix
42° - 36° - 34 °Combination N/A Identification T-1 marked on back side of
PN 5131013 helix
The helix spring should always be adjusted within its limits before a helix change is performed. The normal rate of
change between helix angle steps is 250 RPM under full throttle. This is approximately the same result as in going
from the No.1 to No.4 spring position. NOTE: Increasing spring tension increases engine RPM. RPM changes
may not be evident if other drive or driven clutch components are substandard.
8. Reassemble clutch, installing spring into helix. On all
models the production helix spring hole location is
No.2. Tension the spring 1/3 turn. Install helix key,
thrust washer and snap ring.
9. With drive belt removed, insert a pin punch or drill bit
into a balance hole on the moveable she·ave. Using a
good quality force gauge, record poundage at the
point where the sheave just begins to break away. A
desirable range for the Polaris OEM spring is from 9
to 13 Ibs. To obtain this range, it may be necessary to
move the spring to the No.3 position. NOTE: This
range may not be desirable under some riding
conditions, such as slow trail riding. The higher
spring tension will slow the upshift, decreasing fuel
economy.
7.47
et D
NOTE: Always Install Snap Ring with
Chamfer Towards Helix
8/94
TORQUE-o-MATIC DRIVE
Aluminum Driven Clutch Service - P90
Used to adjust
belt tension. One must
always be install ed.
The driven clutch helix/moveable assembly has several different spring locations which affect clutch shifting and
RPMs. The tightest spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when
pull ing or negotiating a hill. The lighter tension positions will tend to have a slower downshift and a harder upshift.
Moveable
Example: Helix Sheave
B - 1
Spring/ B - 2
Position A - 1
B-3
A - 2
A - 3
Production settings are usually B2
Spring
Tensi on
Soft
The driven clutch ramp buttons are secured by
Torx screws. The ramp buttons should be re-
placed when worn.
After rebuilding, the driven clutch can be reas-
sembl ed.
NOTE: Preload on the driven spring from any of
the various spring positions is 1/3 turn preload ten-
sion (counterclockwi se).
8/94
7.48
SITUATION PROBABLE CAUSE
Harsh drive clutch engage- -Drive belt worn too narrow
ment
- Excessive belt to sheave clearance with
new belt (high performance version with-
out detent shift weight)
Drive belt turn over -Wrong belt for application
-Clutch alignment out of spec
-Engine mount broken or loose
-Driven clutch sheaves have excessive
c
runout, are bent or damaged
Noise in drive system -Broken drive clutch components
-Excessive drive clutch button - tower
clearance
-Bearing failure/ chaincase, jackshaft or
front drive shaft
-Drive chain loose or worn, sprocket teeth
broken
-Driven clutch bushing worn excessively or
spring
broken
-Drive belt surface flat spots
DETENT SHIFT WEIGHTS -Spider roller position remaining in detent
Over rev during initial accel-
eration or during heavy pulling
at low ground speeds.
Engine bogs after engage-
ment.
-Worn belt
-Excessive belt deflection
7.49
TORQUE-O-MATIC DRIVE
TroubleshQoting
-
REMEDY
-Replace
-Perform belt to sheave clear-
ance adjustment with shim
washers beneath spider
- Replace
-Adjust alignment offset
-Inspect, adjust or replace
-Measurement should be tak-
en 12" (30.5 cm) in from outer
circumference on sheave
face. Maximum allowable tol-
erance is .015" (.6 mm).
-Inspect/replace
-Install new buttons or shim
out existing buttons
-I nspect/replace
-Inspect/adjust or replace
-Inspect/replace
-I nspect/replace
-Add spider shim washers
-Add driven washers
-Reduce gear ratio (chaincase
models)
-Replace
-Subtract driven clutch wash-
ers
8/94
TORQUE-O-MATIC DRIVE
Troubleshooting
SITUATION
Engine RPM below specified
operating range, although en-
gine is in properly tuned
Erratic engine operating RPM
during acceleration or load
vari ations
Engine RPM above specified
operating range
8/94
PROBABLE CAUSE
-Wrong or broken drive clutch spring
-Drive clutch shift weight too heavy
-Driven clutch spring broken or installed in
wrong helix location (aluminum clutch)
-Drive belt too long
-Converter sheaves greasy; belt slippage
-Drive clutch binding
-Driven clutch malfunction
-Incorrect drive clutch spring (too high
spring rate)
-Drive clutch shift weights incorrect for ap-
plication (too light)
-Drive clutch binding
-Driven clutch binding
7.50
REMEDY
-Replace with recommended
spring
-Install correct shift weight kit
to match engine application
-Replace spring; refer to prop-
er installation location
-Clean clutches; install new
belt
-Install new belt and/or adjust
belt tension
-Disassemble drive clutch; in-
spect shift weights for wear
and free operation
-Clean and polish stationary
shaft hub; reassemble clutch
without spring to determine
problem area
-Replace ramp buttons
-Inspect moveable sheave for
excessive bushing clearance/
replace
-Install correct recommended
spring
-Install correct recommended
shift weights
-Disassemble and clean
clutch, inspecting shift weights
and buttons. Reassemble
without the spring to further
determine probable cause.
-Disassemble, clean and in-
spect driven clutch, noting
worn sheave bushing and
ramp buttons and helix spring
location

o

, 1/ '

....
I I

l

t

TORQUE-O-MATIC DRIVE

Drive Belt Part Numbers and Applications

c

3211042 ..... Allindys except Indy Sports, Indy lites, Star 1985-1990, Star Trak 1987-1990, Long Trak 1985-1989 3211045 ..... Close tolerance version of 32 11042 3211046 ..... Sport and Sport GT 1987-1991 with P85 Clutch 3211051 ..... lite 1991-1992 3211052 ..... Sport, Sport GT, and Starlite Pilot Build 1990 with P90 Clutch 3211054 ..... Sport, Sport GT 1991-1992 3211055 .... . StarLite 1991-1992 3211053 ..... .lite GT 1992 3211058 ..... lite, lite GT 1993-1995 3211060 . . ... StarLite 1993-1995 3211057 ..... Storm 1993-1995

:'

7.1

8/94

TORQUE-O-MATIC DRIVE P-85 Drive Clutch Information
1972 - 79 Models MODEL
ALL MODELS

SERVICE CLUTCH NO.
1321471

BASIC NO.
20

1980 Models
MODEL
GEMINI 250 APOLLO 340 GALAXY 340 GALAXY 440 TXfTX-C 340 TX 440 TX-L 340 CENTURION 500 TX-L INDY 340

SERVICE CLUTCH NO.
1321471 1321471 1321471 1321471 1321471 1321471 1321471 1321471 1321470 ...

BASIC NO.
20 20 20 20 20 20 20 20 19

1981 Models
MODEL
GEMINI 250 GALAXY 440 CUTLASS 340 CUTLASS SS 340 TX-C 440 TX-L 340 CENTURION INDY 500

SERVICE CLUTCH NO.
1321471 1321471 1321471 1321440 1321470 1321470 1321471

BASIC NO.
20 20 20 13 19 19 20

1982 Models
MODEL
GEMINI 250 CUTLASS SS 440 TX-C 440 TX-L 340 TX-L INDY CENTU RION

SERVICE CLUTCH NO.
1321471 1321440 1321470 1321470 1321 470 1321471

BASIC NO.
20 13 19 19 19 20

1983 Models
MODEL
GEMINI 250 STAR 250 SPORT 440 SS 440 TRAIL 440 INDY CC 340 600 LONG TRACK 440

SERVICE CLUTCH NO.
1321471 1321471 1321440 1321440 1321440 1321470 1321471 1321440

BASIC NO.
20 20 13 13 13 19 21 13

1984 Models

MODEL
STAR 250 SS440 TRA IL 440 600 STAR 250/LT LONG TRACK 440 400 8/94

SERVICE CLUTCH NO.
1321471 1321463 1321463 1321480 1321471 1321440 1321440

BASIC NO.
20 17 17 21 20 13 13

7.2
au

TORQUE-O-MATIC DRIVE

P-85 Drive Clutch Information

c

1985 Models
MODEL SERVICE CLUTCH NO. BASIC NO.

STAR 250 SS440 TRAIL 440 400 600 LONG TRACK 440

1321440 1321463 1321463 1321481 1321480 1321440
SERVICE CLUTCH NO.

13 17
17

22 21 13
BASIC NO.

1986 Models
MODEL

STAR SPRINT SS440 TRAIL 488 400 600 600 LE LONG TRACK 440

1321440 1321493 1321463 1321463 1321481 1321480 1321480 1321440
SERVICE CLUTCH NO.

13 23 17 17 22 21 21 13
BASIC NO.

1987 Models
MODEL

STAR STARTRAK SPRINT SPRINT ES SPORT TRAIL TRAIL (ES) TRAIL 133 SKS 400 400133 SKS 600 LONG TRAK REV 440

1321440 1321440 1321493 1321493 1321463 1321463 1321463 1321463 1321515 132151 5 1321480 1321440
SERVICE CLUTCH NO.

13 13 23 23 17 17 17 17 25 25 21 13
BASIC NO.

1988 Models
MODEL

STAR STARTRAK SPRINT ES SPORT TRAIL & TRAIL DELUXE (ES) TRAIL (ES) TRAIL SKS 400 400 SKS CLASSIC 650 650 SKS LONG TRACK REV 440

1321440 1321440 1321493 1321463 1321463 1321463 1321463 132151 5 1321515 1321516 1321480 1321480 1321440

13 13 23 17 17 17 17 25 25 26 21 21 13

7.3

8/94

TORQUE-O-MATIC DRIVE P-85 Drive Clutch Information 1989 Models MODEL STAR STAR TRAK SPRINT ES LONG TRAK REV 440 SPORT SPORTGT TRAIL & TRAIL DELUXE (ES) TRAIL (ES) TRAILSKS TRAILSP 400 500 500 SKS 500 CLASSIC (ES) 500SP 650 650 SKS SERVICE CLUTCH NO.4 i t:J . 1321440 1321440 1321493 1321440 1321463 1321463 1321463 1321463 1321463 1321463 1321481 1321515 1321515 1321516 1321515 1321480 1321480 BASIC NO. 13 13 23 13 17 17 17 17 17 17 22 25 25 26 25 21 21 1990 Models MODEL STAR STAR TRAK SPRINT ES SPORT SPORT (P-90 BASIC) SPORTGT SPORT GT (P-90) TRAIL & TRAIL DELUXE (ES) SUPERTRAK 400 500 500 SKS 500 CLASSIC (ES) 500SP WIDETRAK 650 650 SKS SERVICE CLUTCH NO. 17 17 23 17 24 17 24 17 17 22 25 25 26 25 17 21 21 8/94 7. 1321463 1321463 1321493 1321463 1321512 1321463 1321512 1321463 1321463 1321481 1321515 1321515 1321516 1321515 1321 463 1321480 1321480 BASIC NO.

1992 Models MODEL STARLITE LITE & LITE DELUXE LITE GT SPORT & SPORT GT TRAIL & TRAIL DELUXE WIDETRAK & SUPERTRAK 440 440 XCR 500 500 SKS 500 SP CLASSIC (ES) 650 RXL RXL SKS 1321538 1321538 1321512 1321512 1321548 1321548 1321549 1321549 1321549 1321549 1321549 1321550 1321551 1321551 1321551 / 27 27 24 24 28 28 29 29 29 2!1 29 30 31 31 31 .. ~_r! 7.5 8/94 . 27 27 24 17 17 24 29 22 25 25 25 26 17 21 21 BASIC NO. BASIC NO. STARLITE LITE SPORT & SPORT GT TRAIL & TRAIL DELUXE (ES) SUPERTRAK LITE GT 400 XC 400 500 500 SKS 500 SP 500 CLASSIC (ES) WIDETRAK 650 RXL 1321538 1321538 1321512 1321463 1321463 1321512 1321481 1321481 1321515 1321515 1321515 1321516 1321463 1321480 1321480 SERVICE CLUTCH NO.TORQUE-O-MATIC DRIVE P-85 Drive Clutch Information c 1991 Models MODEL SERVICE CLUTCH NO.

. 8/94 7. 27 27 27 27 27 27 27 34 34 36 36 36 35 36 36 36 37 37 37 38 38 41 41 40 1994 Models MODEL STARLITE STAR LITE GT INDY LITE INDY LITE DELUXE LITE GT SPORT SUPER SPORT TRAIL DELUXE TRAIL WIDETRAK LX 440 LIQUID IN DY 440 LIQUID SKS CLASSIC TOUR ING CLASSIC 500 EFI 500 SKS XLT XLT SKS XLT SP RXL STORM STORM SKS RXL TOU RING SPORT SKS WIDETRAKGT 440 XCR SERVICE CLUTCH NO. / 1321 576 1321576 1321609 1321609 1321576 1321576 1321577 1321577 1321577 1321578 1321 623 1321623 1321610 1321596 1321597 1321576 BASIC NO.6 . 42 42 42 42 42 42 42 43 43 43 36 36 44 44 44 44 37 37 37 38 48 48 45 42 43 36 ./ 1321596 1321597 1321597 1321597 .TORQU E-O-MATIC DRIVE P-85 Drive Clutch Information 1993 Models MODEL STARLITE STARLITE GT INDY LITE IN DY LITE DELUXE LITE GT SPORT TRAIL DELUXE TRAIL WIDETRAK 440 LIQUID INDY 440 LIQU ID SKS 440 XCR CLASSIC TOURING CLASSIC 500 EFI 500 SKS XLT XLT SKS XL TSP RXL RXL SKS STORM STORM SKS XLT (ELECTRIC START) SERVICE CLUTCH NO. 1321538 1321538 1321538 1321538 1321538 1321538 1321538 1321573 1321573 1321576 1321576 1321576 1321575 1321576 1321576 1321576 1321577 1321577 1321577 1321578 1321578 1321590 1321590 1321582 BASIC NO. 1321596 1321596 1321596 1321596 1321596 1321596 ..

TORQUE-O-MATle DRIVE P-85 Drive Clutch Information c 1995 Models MODEL STARLITE INDY LITE INDY LITE DELUXE LITE GT SPORT SPORT TOURING SUPER SPORT TRAIL DELUXE TRAIL 440 LIQUID INDY 440 LIQUID SKS 440 XCR WIDETRAK LX WIDETRAK GT CLASSIC 500 CARB 500 EFI 500 EFI SKS/PT XLTTOURING XLT XLT SKS/PT XLTSP RXL LT RXL TOURING STORM STORM SKS/PT SERVICE CLUTCH NO. 1321596 1321596 1321596 1321596 1321596 1321596 1321596 1321597 1321611 1321576 1321576 1321634 1321597 1321597 1321609 1321609 1321576 1321576 1321609 1321577 1321577 1321577 1321627 1321610 1321623 1321623 BASIC NO. 42 42 42 42 42 42 42 43 46 36 36 50 43 43 44 44 36 36 44 37 37 37 49 45 48 48 ) 7.7 8/94 .

... . . . . 0-600 in. . .. .. .......... ...... .... .... ..........21/32" (1.. .... . ...... ... .. Tapered Reamer ... .. .6 cm) P-85 Clutches .. ... has received a certificate of completion and displays the Polaris Servicing Dealer decal... .. .. .. Because of the critical nature and precision balance incorporated into the drive clutch... ... ... . Clutch Lubricant ... .... .... ... .. ..... ... ...TORQUE-O-MATIC DRIVE Service Tools A WARNING: All drive clutch maintenance. .. .. .. ... lb........ ...... .. . .. .. . . ... Torque Wrench. ''T'' Handle Clutch Puller . . ....... . . .. . it is absolutely essential that no attempt at clutch disassembly and/or repair be made without factory authorized tools and service procedures..... .7 cm) P-90 Clutches . . ... ....... ..... .... ... ... . . .. ..... ... .. ..5/8" (1 . . ..... . .... . .... . . ..... ...... . . . . . ..... . . .. Clutch Bushing Rebuild Tool Kit .. .. . . . .... ... Driven Clutch Pu ller . . ....... .. Drive Clutch Essential Tools Description Offset Alignment Tool... lb..... .... . ....... .... Spider Spanner Nut Driver . P-85 Compression Tool . disassembly and assembly must be performed only by an authorized Polaris dealer who has attended current model Dealer Service Seminars....... . .. . . ..... . ..... ... .. .. .... . Strap Wrench . ........... .. .. . . .. . . ..... .. 250 ft... . .. Part Number 2870914 2870426 2870506 2870336 2870389 2870338 2870341 5130518 2870547 Not available through Polaris 2870510 Not available through Polaris 2870576 2870985 2871025 2870984 2871056 8/94 7.. . ... ..... ... . . ...... . . .. .. . ...... Holding Fixture Tab . Spider Button Tool .. .... .. .... ... ... .... Offset Alignment Tool ..... . .8 . . .... .. . .. . .... . .. .. .... ... Torque Wrench.... . ... .. . . . .. . .. .. . .... .. . ..... . ..... Holding Fixture ... .... .. ... .... . . .... . Strap Replacement ...... .... . .. . Spider Torquing Tool . .....

under full throttle conditions. SOOO----------..9 8/94 . Relationship Between Drive Clutch Weights And Spring In Maintaining Operating RPM The drive clutch is an RPM and torque sensing unit designed to transfer the maximum amount of horsepower from the engine to the ground.TORQUE-O-MATIC DRIVE Operation c The Polaris torque-o-matic drive system is a centrifugally actuated variable speed belt drive unit.r'-------------ENGAGEMENT 4000--------:. 9000-------------------------8000 . Proper converter setup and adjustments of existing components must be the primary objective in converter operation diagnosis. Therefore. A CAUTION: All converter maintenance repairs must be performed only by an authorized Polaris service technician who has attended a Polaris sponsored service training seminar and understands the proper procedures as outlined in this manual. or the spring rate too high. and belt make up the torque converter system.-:. the maximum RPM will be too great and the drive belt will not move into high gear at the top of the clutch. The drive clutch. modifications or variations of components at random are never recommended.-=-~/-------- 3000------------------------ If the weights are too light. driven clutch. Each clutch comes from the factory with the proper internal components installed for its specific engine model. To gain optimum power this RPM should be maintained. such as adding or removing weights. the maximum desired operating RPM will be reached immediately after clutch engagement. Any unauthorized modifications to clutches. will void the warranty. 7. the moveable sheave will force the belt to climb up the drive clutch sheave and increase vehicle speed.r ------ ______ ENGIN~:OPERATING RANGE 250 RPM __ _ 7000--------------=~---------- ~ 6000-------------4-----------~ . This is accomplished by weights and a spring inside the unit which react to the centrifugal force from the engine RPM. Because of the critical nature and precision balance incorporated into the drive clutch. The spring and weights work in combination.. In a properly set up clutch. it is absolutely essential that no attempt at clutch disassembly and/or repair be made without factory authorized special tools and service procedures. As centrifugal force pushes the weights against the rollers.

keeping the engine out of its power band.10 . the engine RPM will be low and the drive clutch will upshift too fast. 9000------------------------8000------------------------~ ~ 6000 ----7"'l1--.TORQUE-O-MATIC DRIVE Operation 9000------------------------8000-------------------------7000------------------------______ ENGINE OPERATING RANGE ±250 RPM ~ 6000 --------~~~-----------------...- 7000------------------------- 7 --- ENGINE OPERATING RANGE ±250 RPM 5000~/~--------------------- ENGAGEMENT~-------------------------3000-------------------------- If the weights and spring are matched properly... 8/94 7. or spring rate too low.. ~' 4000------------------------- ...... the engine RPM will go to the desired range and remain there on both upshift and backshift.- a: 5000 ENGAGEMENT .7 3000----------------------- If the weights are too heavy.

Because the driven clutch can sense and shift into the proper ratio. the driven clutch becomes dominant and overrides the drive clutch. To do this. Driven Clutch Adjustments The aluminum driven clutch has a provision for varying the torque requirement to change its ratio. Its function is to maintain drive belt tension. preventing slippage and to sense variations in load requirements necessary to maintain optimum engine torque output and load requirements from the track.11 8/94 .TORQUE-O-MATIC DRIVE Driven Clutch Operation The driven clutch operates in conjunction with the drive clutch. Aluminum Driven Clutch 7. engine RPM will remain within the specified range. it relocates the spring in the helix which in turn increases or decreases the amount of load required to change the ratio. When the load on the driven clutch is increased and becomes greater than the torque delivered from the engine. Output torque is transmitted through the chaincase jackshaft and chaincase to the front drive shaft and track. The driven clutch downshifts into a ratio which will supply the amount of torque needed for the increased load.

174" 1.. Gold Red Blue Orange 34· 34· 34· 36· N-1 Mod.20T' Yellow .0 wt. P-1 06 04 '.0" 11..5" 12. 6300 6000 6800 7800 7800 6300 1321449 1321450 1321455 1321459 1321458 1321454 Spring Color.0" 12.1 74" 1.5 04/57.20T' Gold .12 .. P.17T' Brown .174" 1985 HIGH ELEVATION RECOMMENDATIONS Machine Model Shift Weight 5000 Feet to 8000 Feet Clutch Spring Brown Orange Driven Helix 36· 36 · Chaincase Gearing Shift Weight 8000 Feet to 12000 Feet Clutch Spring Driven Helix 36· 36· Chaincase Gearing OptionsNonWarranty Star SS 08 07 ..5 07/52 .200" White .0" Driven Helix Angle 36 · 36· Gearing Chain Pitch/Type Direct Drive Direct Drive 19/35 64P Silent 19/35 19/35 63P Silent 19/39 64P Silent EC25PS-06 EC44-2PM-3100 EC44-2PM-2100 EC40PL-02 EC60PL-02 EC44-2PM-5000 N-1 Mod..TORQUE-O-MATIC DRIVE Data 1985 PRODUCTION SETUP Machine Model Star SS Trail 400 600 LongTrak Engine Model Operating Production RPM±200 Clutch Part No.1 06 04 Gold Red Blue Silver 34· 34· 34 · 36· 19/35 19/35 19/35 19/39 ftft • • • ** ••• * •••• 8/94 7.. Brown ...5 N-1 Mod. Bore Taper Diameter 1.. D.192" Shift I.5 05/53.17T' Clutch Center Distance 12.5 34· 34· 34· 36° 1. *_ft •• .0" 12.0" 12.200" Gold . 6 Tooth Front Sprocket ft • • • • Indy Trail Indy 400 600 LongTrak N-1 Mod.... 51. . 19/35 19/35 21/35 19/39 08 07 Red/white Orange ..lGram 08/47.. Wire Dia. 51..174" 1.174" 1..

.5" 12.174 1. 6300 6500 6000 7000 7700 7800 6000 1321449 1321451 1321456 1321450 1321461 1321459 1321458 1321454 Spring Color.177 RedlWhite . Brown .174 1..192 Blue ..174 1.192 Shift wt..0" 11.. 06 04 8000 Feet to 12000 Feet Clutch Spring RedlWhite Blue/Gold RedlWhite RedlWhite Red or Blue/Gold Blue/Gold Silver Driven Helix 36· 36· 36· 36· 34· 34· 36· ..13 8/94 .....200 Brown ..0 15/55. 600 LE LongTrak 08 05 07 M-1 Mod.5 Bore Taper Diameter 1.174 1.. 06 04 5000 Feet to 8000 Feet Clutch Spring RedlWhite Blue/Gold Orange Orange Gold Blue/Gold Orange Driven Helix 36 · 36· '36· 36· 34· 34· 36· Chaincase Gearing Shift Weight 08 06 06 M-1 Mod.177 1. P-1 or M-1 Mod..5" 11. LD..174 Clutch Center Distance 12.207 White .0" c 600. ** .5 04/57.5 07/52. ***** Chaincase Gearing . Wire Dia.5 05/53. ***** ***** 21/35 19/35 21/35 19/39 21/35 19/35 21/35 19/39 7.174 1.207 Yellow . 600 LE LongTrak 1986 HIGH ELEVATION RECOMMENDATIONS Machine Model Shift Weight Star Sprint & Sprint ES SS Indy Trail Indy 400 600./Gram 08/47.TORQUE-O-MATIC DRIVE Data c 1986 PRODUCTION SETUP Machine Model Star Sprint & Sprint ES SS Trail Indy 400 Engine Model Operating Production RPM±200 Clutch Part No. 50.0" 12.0" 12..0 10/51. M-1 Mod.5 10/Mod.207 Blue/Gold .0" Driven Helix Angle 36· 36· 36· 36· 34· 34· 36° Gearing Chain Pitch/Type Direct Drive Direct Drive Direct Drive 21/35 19/35 21/35 19/39 EC25PS-06 EC34-2PM-01/02 EC44-2PM-3100 EC50PM-01 EC40PL-02 EC60PL-02 EC44-2PM-5100 - 12.

06 04 Clutch Spring RedlWhite Blue/Gold Gold Orange Gold Blue/Gold Orange Driven Helix 36· 36· 34· 36· 34· 34· 36· Chaincase Gearing Shift Weight 08 06 10 M-1 Mod.0" Driven Helix Angle 36· Gearing Chain PitchfType Direct Drive 15/39 EC25PS-06 EC34-2PM-01/02 EC34-2PM-03 EC50PM-01 EC40PL-02 EC60PL-02 EC44-2PM-5100 6500 6500 7000 7700 7800 6000 1321451 1321456 1321461 1321477 1321459 1321458 1321454 05/53.. I.200 Gold . Drive 15/39 ***** Star Star Trak Sprint & Sprint ES Indy Sport Indy Trail (All) Indy 400 600 Lon~Trak .174 Clutch Center Distance 12..174 1.174 1.192 Shift Wt. " 6300 1321449 Spring Color..TORQUE-O-MATIC DRIVE Data 1987 PRODUCTION SETUP Machine Model Star StarTrak Sprint & Sprint ES Indy Sport Trail (All) Indy 400 600 LongTrak (RLR) Engine Model Operating Production RPM±200 Clutch Part No.0" 12.0" 36· 34· 36· 34· 34· 36° Direct Drive 17/35 21/35 19/35 21/35 19/39 49. 06 04 8000 Feet to 12000 Feet Clutch Spring RedIWhite Blue/Gold Blue/Gold RedIWhite Red or Blue/Gold Blue/Gold Silver Driven Helix 36· 36· 34· 36· 34· 34 · 36· Chaincase Gearing D.5 10/51. P-1 or M-1 Mod. M-1 Mod..174 11.0" 12.174 1.192 Blue/Gold .7 101M 1.0 04/57.lG ram 08/47.207 RedlWhite . ***** ***** 17/35 21/35 19/35 21/35 19/39 17/35 21/35 19/35 21/35 19/39 (RL ) 8/94 7. .*.207 Blue/Gold . Wire Dia. Brown .5 ) 1987 HIGH ELEVATION ijECOMMENDATIONS Machine Model 5000 Feet to 8000 Feet Shift Weight 08 05 10 M-1 Mod.192 RedlWhite .177 1.5 Bore Taper Diameter 1. D.207 Yellow .14 .174 1.5" 12.0" 12.7 10/51.5 10/A 55.5" 11.

RPM±200 6300 Production Clutch Part No.5 10/A 55.7 10/51.174 11.192 RedlWhite .207 Gold .174 1. 1321449 Spring Color. Brown .207 RedlWhite .0" Driven Helix Angle 36· Gearing Chain PitchfType Direct Drive 15/39 Direct Drive 17/35 21/35 19/35 19/35 19/35 18/35 21/35 19/35 19/39 EC25PS-06 EC34-2PM-02 EC34-2PM-03 EC50PM-01 EC40PL-02l03 6500 6500 7000 8000 1321456 1321461 1321461 132 1485 1321459 1321459 132 1458 132 1478 05/53.0" 36· 34· 36· 34· .15 8/94 .!Gram 08/47. Wire Dia.200 Gold .177 1. *""""-- o Sprint ES Indy Sport Indy Trail (All) Trail SKS 400 Classic Indy 400 400 SKS 650 650 SKS LongTrak (RLR) 17/35 2 1/35 19/35 19/35 19/35 19/35 21/35 19/35 19/39 17/35 21/35 19/35 19/35 19/35 19/35 21/35 19/35 19/39 10M Blue 10 Red Silver 34· 36 · 10M White 10 Blue Silver 34· 36· ) 7.208 ShiftWt.192 Blue .TORQUE-O-MATIC DRIVE Data c 1988 PRODUCTION SETUP Machine Model Star StarTrak Sprint ES Indy Sport Trail (All) Trail SKS 400 Classic Indy 400 400 SKS 650 650 SKS LongTrak (RLR) Engine Model Operating .174 Clutch Center Distance 12...7 1.0 EC65PL-01 EC44-2PM-4100 7800 6300 1.. LD.174 12.174 1.1 74 1.0 1988 HIGH ELEVATION RECOMMENDATIONS Machine Model Shift Weight Star Star Trak 08 05 10 M-1 Mod or 10M 10M Red 5000 Feet to 8000 Feet Clutch Spring RedlWhite Blue Gold Orange RedlWhite Blue Driven Helix 36· 36· 34· 36· 34· Chaincase Gearing Shift Weight 08 06 10 10M Red 10M Red 8000 Feet to 12000 Feet Clutch Spring RedlWhite Blue Blue RedlWhite Blue Driven Helix 36· 36· 34· 36· 34· Chaincase Gearing 15/39 *"" ••• 15/39 ""*ft.5" 11..5 Bore Taper Diameter 1.5" 12./ 10M Blue/47.207 Silver .0" 12.0" 12.5 10/51.* .0" 34· 36° 10A 55.

0" 12.5" 12.lGram 08/47. GT Indy Trail Super Trak Trail (All) Trail SKS Indy 400 Indy 500 SKS Classic 650 650SKS LongTrak (RLR) Engine Model Operating RPM±200 6300 Production Clutch Part No.0" 36" Direct Drive 17/35 21/39 21 /35 19/35 19/35 19/35 18/35 19/35 21/35 19/35 19/39 34" 36" 36 " 34" 36" 10M Blue/47.**** 8000 Feet to 12000 Feet Shift Weight 08 06 10 or 10M Blue 10M Blue 10M Red 10M Red 10M Blue 10M Blue 10 Clutch Spring RedlWhite Blue Blue or Gold RedlWhite RedlWhite Blue Blue Blue Silver Driven Helix 36" 36 " Chaincase Gearing •••• * 15/39 15/39 ***** .0" Driven Helix Angle 36" Gearing Chain PitchfType Direct Drive 15/39 EC25PS-06 EC34-2PM-02 EC34-2PM-03 EC50PM-03 EC50PM-01/02 EC40PL-02 EC50PL-01/02 6500 6500 6600 7000 8000 7800 1321493 1321461 1321461 1321461 1321459 1321459 1321459 1321493 1321458 1321478 05/53.5" 11.0 1989 HIGH ELEVATION RECOMMENDATIONS Machine Model Shift Weight Star Star Trak Sprint ES Indy Sport.177 1. Brown .174 12.0" 34· 36° 55.5 10/5 1.16 .200 RedlWhite .7 1.5 10M ) EC65PL-01 EC44-2PM-4100 7800 6300 10/A 1.7 10/51.174 1.192 Brown .174 11.207 RedlWhite .192 Blue 47.0" 12.208 Gold .174 1.5 Silver . 1321449 Spring Color.1 74 1. Wire Dia.207 Silver .* ••• 17/35 21/39 21/35 19/35 19/35 19/35 18/35 21/35 19/35 19/39 34" 36" 36 " 17135 21/39 21/35 19/35 19/35 19/35 18/35 21 /35 19/35 19/39 34" 36" 34" 36" 34" 36" 34" 36" 8/94 7.174 Clutch Center Distance 12.200 Brown .D.7 10/51.TORQUE-O-MATIC DRIVE Data 1989 PRODUCTION SETUP Machine Model Star StarTrak Sprint ES Indy Sport.5 Bore Taper Diameter 1.1 74 1.0" 12. GT SuperTrak Indy Trail (All) Trail SKS Indy 400 Indy 500 500 SKS 650 650 SKS LongTrak (RLR) 08 05 10 10M M-1 Mod or 10M 10M Red 10M Blue 10M Blue 10 5000 Feet to 8000 Feet Clutch Spring RedlWhite Blue Gold RedlWhite Orange RedlWhite Blue Blue Red Silver Driven Helix 36" 36" 34" 36" 36" Chaincase Gearing .208 Shift Wt.174 1. I.0" 12.0 10A 55.

0" 12.DJGram 08/47.174 1. Wire Dia.200 Brown .174 1.1 92 Brown . Brown .174 1.207 RedlWhite . GT Indy Trail Super Trak Indy Trail (All) Indy 400 Indy 500 SKS Classic WideTrak 650 650 SKS Engine Model Operating Production RPM±200 Clutch Part No.160 GT 1.TORQUE-O-MATIC DRIVE Data c 1990 PRODUCTION SETUP Machine Model Star StarTrak Sprint ES Indy Sport.208 RedlWhite .7 10M Blue 47.174 1.177 12.7 1.0" 36· 34· 36· 36· 34· 36· EC50PL-03 EC65PL-01 7800 7800 10 10 51.0" 12.5" 12.174 1.192 Gold .0" 12.7 10/51.174 Clutch Center Distance 12.7 10/51.207 Shift WI.0" 12.5" 11 .174 1.0" Driven Helix Angle 36· Gearing Chain Pitch/Type Direct Drive 15/39 Direct Drive 17/35 21/39 21/35 19/35 19/35 18/35 19/35 19/4 1 21/35 19/35 EC25PS-06 EC34-2PM-02 EC34-2PM-03 EC50PM-03 EC50PM-01/02 EC40PL-02 EC50PL-01/02 6500 6500 6600 7000 8000 7800 1321493 1321463 1321512 132 1463 1321463 1321481 1321515 1321515 1321516 1321516 1321480 05/53. 6300 1321463 Spring Color.0" 36· 34· 1990 HIGH ELEVATION RECOMMENDATIONS Machine Model 5000 Feet to 8000 Feet Shift Weight 08 05 10 10M 10M 10M Red 10M Blue 10M Blue 10M Blue Clutch Spring RedlWhite Blue Gold RedlWhite RedlWhite Blue Blue RedlWhite Blue Driven Helix 36· 36· 34· 36· 36· 34· 36· 36 · 34· Chaincase Gearing ***** 8000 Feet to 12000 Feet Shift Weight 08 06 10 or 10M Blue 10M Blue 10M Red 10M Red 10M Blue 10M White 10M White Clutch Spring RedlWhite Blue Blue or Gold RedlWhite RedlWhite Blue Blue RedlWhite Blue Driven Helix 36· 36· 34· 36 · 36· 34· 36· 36· 34· Chaincase Gearing ••• ** Star Star Trak Sprint ES Indy Sport.1 74 11 .5 10/51.'***'* 15/39 ***** 17/35 21/39 21/35 19/35 19/35 18/35 19/41 21/35 19/35 17/35 21/39 21/35 19/35 19/35 18/35 19/41 21 /35 19/35 7.1 92 Blue 47.5 Bore Taper Diameter 1. GT SuperTrak Indy Trail (All) Indy 400 Indy 500 500 SKS WideTrak 650 650 SKS 15/39 .5 Silver .5 10M 1.17 8/94 .200 RedlWhite . I.

192 Blue .174 1.7 10/51.200 RedlWhite . GT SuperTrak Indy Trail (All) Indy 400 Indy 500 500 SKS WideTrak 650/RXL RXLSKS .174 1.5" 12. I.200 Brown .0" 11 .208 RedlWhite .200 RedlWhite .192 Brown ...0" 36' 36' 1991 HIGH ELEVATION RECOMMENDATIONS Machine Model 5000 Feet to 8000 Feet Shift Weight 08 05 10 10M 10M 10M Red 10M Blue 10M Blue 10M Blue Clutch Spring RedIWhite Blue Gold Red/white Red/white Blue Blue RedIWhite Blue Driven Helix 36' 36' 36' 36' 36' Chaincase Gearing * •••• 8000 Feet to 12000 Feet Shift Weight 08 06 10 or 10M Blue 10M Blue 10M Red 10M Red 10M Blue 10M White 10M White Clutch Spring RedIWhite Blue Blue or Gold Red/white Red/white Blue Blue Red/White Blue Driven Helix 36' 36' 36' 36' 36' 34' 36' 36 ' 36' Chaincase Gearing * •••• StarLite Indy Lite Indy Sport.5" 11 .192 Gold .0" 12.TORQUE-O-MATIC DRIVE Data 1991 PRODUCTION SETUP Machine Model StarLite Indy Lite Indy Sport.174 Clutch Center Distance 12.0" 12.1 74 1. 15/39 .207 Silver ..0" 12.7 10/51 . 7. Wire Dia.lGram 08/47.160 GT 1.7 10/51.5 10/51.18 .174 1..174 1.. Brown ..5 10M 34' 36' EC50PL-06 EC65PL-02l03 7000 7800 10 10AL 53 1.174 1. GT Indy Trail Super Trak Indy Trail (AU) Indy 400 Indy 500 SKS/SP Classic WideTrak 650/RXL RXLSKS Engine Model Operating Production RPM±200 Clutch Part No..D.0" 12.*. 6300 6500 6800 6600 7000 8000 7800 1321514 1321513 132 1507 1321498 1321461 1321459 1321502 1321 502 1321501 1321508 1321517 Spring Color.207 Shift Wt.7 Bore Taper Diameter 1.0" Driven Helix Angle 36 ' 36' 36' 36' 36' Gearing Chain PitchfType Direct Drive Direct Drive 16/35 21/39 21/35 19/35 19/35 18/35 19/35 19/41 21/35 19/35 EC25PS-07 EC34-2PM-03 EC44-3PM-01 EC50PM-03 '\ EC50PM-01/02 EC40PL-02l04 EC50PL-01 /0204/05 10M Bluel 47. 17/35 2 1/39 21/35 19/35 19/35 18/35 19/41 2 1/35 19/35 17/35 2 1/39 21/35 19/35 19/35 18/35 19/41 21135 19/35 34' 36' 36' 36' 8/94 .177 12.174 1.

160 Bore Taper Dia.207 Red! White .00" 12.200 EC50PM-01 102 1321539 1321540 Red! White ./G ram 10M Red Clutch Center Distance 11 .174 10 1.160 10MB 1.00" 12.00" 36° B-2 36° 16:35 16:39 21:39 #2 12.174 10 1. Driven Helix Angle & Location 36° B-2 Chaincase Gearing Direct Drive 5 Tooth Direct Drive 6 Tooth 16:39 10.00" 12.174 1.TORQUE-O-MATIC DRIVE Data c 1992 PRODUCTION SETUP Operating RPM ± 200 6300 Production Clutch Part ~o.200 Brown .160 10 1.19 8/94 . 1321514 Spring Color. 1.160 Machine Model Star Lite Engine Model EC25PS-Q7 Shift Wt.00" 36° 21:39 19:41 21 :39 21:39 21:39 20:39 21:39 20:39 20:35 20:35 21:39 #2 36° #2 34 ° #2 36° #2.174 1. 36° #2 36 ° #2 36° #2 36° . I. D.192 Sport 440 Sport 440 GT Trail Trail Deluxe EC44-3PM-01 6800 7000 1321523 Brown .174 10 1. Wire Dia. #2 t ' 7.177 1.50" .00" 12.192 SuperTrak WideTrak 440 Indy 440XCR Indy 500 Classic 500 SP EFI 500 SKS Indy 650 RXL RXLSKS EC50PM-03 EC50PL-06 EC50PL-02 EC50PL-01 EC50PL-04 105 EC50PL-07 EC65PL-02 EC65PL-03 6600 7000 7800 8000 7800 7800 8000 8000 1321541 1321545 1321547 1321547 1321543 1321544 1321543 1321546 1321546 Brown .174 10 1.625" 11.03" 36° B-2 36° B-2 12.177 1.00" 12. Orange .00" 12.00" 12.174 1.196 Indy Lite Lite Deluxe Indy Lite GT EC34-2PM-0302 EC34-2PM-04 6500 7000 1321513 1321552 1321507 Gold .200 Blue Blue Gold Gold Blue Blue 10MB Bushed 10MB Bushed 10 M Bushed 10 M Bushed 10 AL Bushed 10AL Bushed 1.00" 12.

9000 Ft. Drive 6 Tooth 16:39 Shift Weight 10M Red 10M 10M White 10 6000 Ft.. Drive 5 Tooth D.. to 9000 Ft.!<~ .20 .... Drive 6 Tooth 16:39 Red! White Red! White Red! White Red! White Blue Blue 16:35 16:39 21:39 Gold 16:35 16:39 21:39 16:35 16:39 21:39 10 10M Red! White Red! White Red! White Blue Blue ) 10 21:39 10M 21:39 21:39 WideTrak 10 19:41 10M Blue 10M Red 10M White Bushed 10M Blue Bushed 19:41 19:41 440 Indy 440 XCR 10M White 10M White Bushed 10M Blue Bushed 21:39 21:39 34· #2 21:39 21:39 34· #2 36· #2 Indy 500 Classic Gold 21:39 20:39 Blue 21 :39 20:39 500 SP EFI 500 SKS 10M Blue Bushed 10 Bushed Gold 36· #2 36· #2 21:39 20:39 10M Blue Bushed 10M Blue Bushed Blue 36· #2 36· #2 21:39 20:39 Blue 36· #2 36 · #2 21:39 20:39 650/RXL RXLSKS Blue 20:35 21:39 Blue 20:35 21:39 Blue 20:35 21:39 8/94 7. Clutch Spring Blue Blue Blue or Gold Blue Gold Red! White Red! White Red! White Blue Blue Driven Helix 36 e B-2 36 e B-2 36 e B-2 36 e B-2 36 e #2 36 · #2 36 · #2 Chaincase Geari.TORQUE-O-MATIC DRIVE Data 1992 HIGH ELEVATION RECOMMENDATIONS 3000 Ft. Machine Model StarLite Indy Lite Deluxe Indy Lite GT Sport 440 Sport 440 GT Trail Trail Deluxe SuperTrak Shift Weight 10M Red 10 10M Blue 10 Clutch Spring Red! White Blue Gold Driven Helix 36 e B-2 36 e B-2 36 e B-2 36 e B-2 36 e #2 36 e #2 36· #2 34· #2 36· #2 36· #2 Chaincase Gearing D. Drive 5 Tooth D. Drive 5 Tooth D. Drive 6 Tooth 16:39 Shift Weight 10M Red 10M 10M White or 10M Red 10 or 10M Blue 10M Blue 10M Blue 10M White 10M Red 10M Red Bushed 10M White Bushed or 10M Red Bushed 10M White Bushed or 10M Blue Bushed 10M White Bushed \". to 6000 Ft.. Clutch Spring Gold Gold Gold Driven Helix 36 e B-2 36 e B-2 36 e B-2 36 e B-2 36 e #2 36 e #2 36· #2 34 e #2 34· #2 Blue 36· #2 21:39 20:39 21:39 21:39 Chaincase Gearing D.ng D. to 12000 Ft.

00" 1.lGram 10M Red Chaincase Gearing 15:41 36S B-2 36S B-2 16:39 36S B-2 36° 16:39 21:39 #2 #2 34 ° 21 :39 20:39 21:39 21:39 20:39 21:39 20:39 21:39 20:39 21:39 20:39 23:37 #2 36 ° #2 36 ° #2 36° #2 34° #2 34° c 7.236" Driven Helix Angle & Location Machine Model StarLite StarLite GT Indy LitelGT Lite Deluxe Engine Model EC25PS-07 Shift wt.190 12.190 12.218 Sport Brown .00" 1.21 8/94 .200 Trail Deluxe EC44-3PM-0 1 6800 1321568 Brown .00" 36° 19:41 10 Bushed 1.160 11.190 12.00" 10 1.207 1321581 Blue! Gold .00" 10 1.200 Trail EC50PM-01 7000 1321570 Red! White .TORQUE-O-MATIC DRIVE Data 1993 PRODUCTION SETUP Operating RPM ± 200 6300 Production Clutch Part No.160 12.190 12.192 WideTrak EC50PM-06 7000 1321567 Brown .030" Bore Taper Dia.160 Clutch Center Distance 12. Wire Dia.190 12.207 8000 8000 8000 Gold .207 10 Bushed 10 MB Bushed 10 MB Bushed 10 M Bushed 10 M Bushed 10M Bushed 10 AL Bushed 10-64 Bushed 1.00" 1.00" 1. I.207 Gold .D. Orange .00" 1.177 12.207 EC45PL-01 8000 7800 7800 1321564 1321569 1321544 1321569 1321571 1321546 Blue . 1321514 Spring Color.00" 36° B-2 16:35 10 1.177 12. 1.190 12.00" 36 ° 1.196 EC34-2PM-04 7000 1321560 1321561 EC44-3PM-01 6800 1321568 SilverI Gold .177 12.207 EC50PL-04 EC50PL-05 EC50PL-07 EC58PL-01 EC65PL-05 EC75PL-01 Gold .160 12.207 Blue .200 440 Indy 440 SKS 440 XCR Classic Classic Touring 500 SP EFI 500 EFI SKS XLTIXLT SP XLT SKS RXL RXLSKS Storm Storm SKS EC45PL-02 7800 1321580 Gold .50" 1.

5° B-2 36° B-2 36.5° B-2 36.5° B-2 36 ° B-2 36° B-2 36° Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White or 10M Red 10 or 10M Blue 10 or 10M Blue 10M Blue 10M White 10M Red Bushed 10M Red Bushed 10M Red Bushed 10M White or 10M Red 10M White or 10M Red 10M White or 10M Blue 10M White or 10M Blue 10M Red Bushed 10M Red Bushed 10M White Bushed 10M White Bushed 10 Bushed 9000 Ft. Machine Model StarLite StarLite GT Lite GT Lite Lite Deluxe Sport Trail Deluxe Trail WideTrak Shift Weight 10M Red 10M Blue 10 10 10 Bushed 10 Bushed 10M White Bushed 10M White Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10 Bushed 10 Bushed 10-60 Bushed Clutch Spring Red! White Gold Driven Helix 36.5° B-2 36 ° B-2 36. Clutch Spring Blue Blue Gold Blue Gold Blue Gold Redl White Driven Helix Chaincase Gearing 15:41 16:39 36S B-2 36. to 12000 Ft.TORQUE-O-MATIC DRIVE Data 1993 HIGH ELEVATION RECOMMENDATIONS 3000 Ft.5° B-2 36° Red! White Red! White Red! White Red! White Blue 16:35 16:39 21:39 19:41 Gold Gold Red! White Red! White Blue 16:35 16:39 21 :39 19:41 16:35 16:39 21:39 19:41 #2 36° #2 36° #2 36° #2 34° 21:39 #2 34° 21:39 Red! White Blue ) #2 34° #2 34° #2 34° #2 36° #2 36° #3 36° #3 36° #3 34 ° 21:39 440 Indy #2 Blue 34° #2 34° #2 36° #2 36° #2 36 ° #2 36° #2 34° 20:39 #2 Blue 34° #2 34° #2 36° #2 36° #3 36 ° #3 36 ° #3 34° 20:39 440SKS Blue 20:39 440 XCR Blue 21:39 Blue 21 :39 Blue 21:39 Classic Gold 21:39 Blue 21:39 Blue 21:39 Classic Touring 500 EFI Gold 20:39 Blue 20:39 Blue 20:39 Gold 21 :39 Blue 21:39 Blue 21:39 500 EFI SKS Gold 20:39 Blue 20:39 Blue 20:39 XLT/XLT SP Gold 21:39 Blue 21:39 Blue 21:39 XLT SKS Gold 34° 20:39 Blue 34 ° 20:39 Blue 34 ° 20:39 RXL Blue 36° 20:35 Blue #2 Blue 36° #2 34° #2 21:39 34 °#2 or36° #3 34 °#2 or 36° #3 34° 20:35 Blue 36° 2# 36° #2 34° 20:35 RXL SKS Blue 21:39 Blue 21:39 Storm Storm SKS SilverI Gold 23:37 SilverI Gold 23:37 SilverI Gold 21:37 8/94 7. to 9000 Ft. Clutch Spring Gold Gold Driven Helix 36.5° B-2 36.5° B-2 36° Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White 10 10 10M Bushed 10M Blue Bushed 10M Red Bushed 10M Red Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M White Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10A Bushed 6000 Ft. to 6000 Ft.22 .

.207 Gold .177 12.00" 12. Orange .207 Blue .00" 1.. 500 EFI SKS XLTIXLT SP ( XLT SKS RXL RXL Touring Storm Storm SKS EC50PM-03 EC50PL-06 EC45PL-02 EC45PL-01 EC50PL-05 EC50PL-08 EC50PL-07 EC58PL-01 EC65PL-05 EC65PL-06 EC80PL-01 8000 1321ro7 7800 8000 8000 1321569 1321571 1321608 7800 8000 7800 1321580 1321564 1321606 7000 1321583 Brown .207 Gold .207 10 Bushed 10MB Bushed 10MB Bushed 10M Bushed 10 M Bushed 10 M Bushed 10AL Bushed 10-62 Bushed 1.200 Gold .200 Red! White ..160 1.030" Shift Wt.174 1.1 92 WideTrak GT WideTrak LX 440 Indy 440 SKS 440 XCR Classic Classic Touring 500 SP EFI .160 ~ 1.00" 1.160 11.1 90 12.190 1.TORQUE-O-MATIC DRIVE Data 1994 PRODUCTION SETUP Machine Model Engine Model Operating RPM ± 200 6300 Production Clutch Part No.00" 1..23 8/94 .---1.177 12. 1321599 Spring Color..24" Driven Helix Angle & Location Chaincase Gearing Star Lite Star Lite GT Indy Lite/GT Lite Deluxe EC25PS-Q7 10M Red 36S B-2 36.lGram Bore Taper Diamet er 1.00" 36° 19:41 21:39 20:39 21:39 21:39 20:39 21:39 20:39 21:39 20:39 21:39 20:39 23:37 21:37 #2 34° #2 36° #2 36° #2 36 ° #2 34° 36° 12.50" 1.218 Sport Sport SKS Super Sport Trail Deluxe Trail EC44-3PM-01 Brown .200 Brown .160 Clutch Center Distance 12.00" 12.207 Blue .00" 10 Bushed 10 10 \ 10 1.207 Blue .00\ #2 42-36-34° Combination G:J?> 7.190 12.5° B-2 36° B-2 15:41 16:39 1.D.00" 1"\ 16:35 36S B-2 36° 16:39 21:39 .00" 12.190 V 12. Wire Dia.196 EC34-2PM-04 -02 7000 1321601 1321602 6800 1321594 1321619 EC50PM-02 EC50PM-01 6800 7000 1321592 1321570 SilverI Gold .190 12. I.190 #2 12.207 Gold .

5" #B-2 36. Clutch Spring Blue Blue Gold Blue Gold Blue Gold Red! White Gold Red! White Red! White Red! White Red! White Blue Driven Helix 36. Machine Model StarLite StarLite GT Lite GT Lite Lite Deluxe Sport Sport SKS Super Sport Shift Weight 10M Red 10M Blue 10 10 10AL Bushed 10 Bushed 10 Bushed 10 Bushed 10 Bushed 10M White Bushed 10M White Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed Clutch Spring Red! White Gold Driven Helix 36. 36° #2 34 ° #2 34 ° #2 34 ° #2 36° #2 36° #3 36° #3 36° #3 34° Chaincase Gearing 15:41 16:39 Red! White Red! White Red 16:35 16:39 17:35 Gold Gold Gold 16:35 16:39 17:35 16:35 16:39 17:35 Trail Deluxe Trail Red! White Red! White Red! White Red! White Blue 22:41 21 :39 Red! White Red! White Red! White Red! White Blue 22:41 21:39 22:41 21:39 WideTrakLX 19:41 19:41 19:41 WideTrak GT 440 Indy 19:41 19:41 19:41 21:39 21 :39 21:39 440 SKS Blue 20:39 Blue 20:39 Blue 20:39 440 XCR Blue 21:39 Blue 21 :39 Blue 21:39 Classic Gold 21:39 Blue 21:39 Blue 21:39 Classic Touring Gold 20:39 Blue 20:39 Blue 20:39 500 EFI Gold 21:39 Blue 21 :39 Blue 21 :39 500 EFI SKS Gold 20:39 Blue 20:39 Blue 20:39 XLTIXLT SP 10M Gold Blue Bushed .5" #B-2 36.24 . Clutch Spring Gold Gold Driven Helix 36.5° #B-2 36.5° #B-2 36° #B-2 36° #B-2 36° #B-2 36° #2 36° #2 36° #2 . 10M Blue Bushed 10 Bushed 10 Bushed 10-60 Bushed Gold 21:39 Blue 21:39 Blue 21:39 XLT SKS 34 ° 20:39 Blue 34 ° 20:39 Blue 34 ° 20:39 RXL Blue 36° #2 36 ° #2 Stock 20:35 Blue 34°#2 or 36 ° #3 34°#2 or36 ° #3 Stock 20:35 Blue 34°#2 or 36° #3 34°#2 or 36 ° #3 Stock 20:35 RXL Touring Blue 21:39 Blue 21:39 Blue 21:39 Storm Storm SKS Blue 23-37 21-37 Blue 23-37 21 -37 Blue 23-37 21-37 8/94 7.5° #B-2 36° #B-2 36° #B-2 36° #B-2 36° #2 36° #2 36° #2 36° #2 34° #2 34° #2 34 ° #2 36° #2 36° #2 36 ° #2 36° #2 34° Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White 10 10 10AL Bushed 10M Bushed 10M Bushed 10M Blue Bushed 10M Bushed 10M Red Bushed 10M Red Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M White Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10-58 Bushed 6000 Ft. to 6000 Ft.TORQUE-O-MATIC DRIVE Data 1994 HIGH ELEVATION RECOMMENDATIONS 3000 Ft. to 12000 Ft.5° #B-2 36° #B-2 36° #B-2 36° #2 36° #2 36° #2 36° #2 36° #2 34 ° #2 34 ° #2 34 ° #2 36° #2 36° #3 36° #3 36° #3 34° Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White or 10M Red 10 or 10M Blue 10 or 10M Blue 10 or 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M White Bushed 10M Blue Bushed 10M Red Bushed 10M Red Bushed 10M Red Bushed 10M White Bushed or 10M Red Bushed 10M White Bushed or 10M Red Bushed 10M White Bushed or 10M Blue Bushed 10M White Bushed or 10M Blue Bushed 10M Red Bushed 10M Red Bushed 10M White Bushed 10M White Bushed 10 Bushed or 10ALBushed 9000 Ft. to 9000 Ft.

I.218 Brown .!Gram Bore Taper Diamet er 1.00" 12.207 Gold . WideTrak LX 440 Indy 440 SKS 440 XCR Indy 500 Classic 500 EFI 500 EFI SKS XLT/XLT SP XLT SKS XLT Touring 600 XCR RXL RXL Touring Storm Storm SKS EC50PM03 EC50PL06 EC45PL02 6600 7000 8000 1321 583 1321583 1321580 #2 36° #2 34° #2 1.00" 36° 21:39 #2 1.190 12.00" 12. Wire Dia.D.207 Shift WI.07 .00" 36.192 Red! White .177 12.200 Gold . Orange ..00" 12.190 1.~ #2 - 7.190 12.00" 34° 21:39 21:39 21:39 21:39 20:39 EC45PL05 EC50PL04 EC50PLE04 EC50PL07 8250 7750 7750 8000 1321643 1321569 1321606 1321569 #2 36° #2 36° #2 36 ° #2 1. 1321599 1321601 1321602 1321594 1321619 Spring Color.00" 12.1 92 Red! White .177 1.207 Blue .1 77 12.196 SilverI Gold .207 Gold .190 1.00" 36° 20:39 Trail Deluxe EC50PME04 7000 1321592 #2 1.00" 36° 19:41 19:41 ·21:39 20:39 WideTrak GT .160 Clutch Center Distance 12.190 1.207 Gold .00" 34° 21:39 20:39 EC58PL03 8000 1321571 #2 1..190 12.160 1.50" 34° 8250 13216.1 60 1.00" 12.177 12.190 1.25 8/94 .177 1.160 12.00" 12..207 Gold .190 1.192 Brown .00" 34° 20:39 21:39 20:35 21:39 23:37 20:35 EC58PLE04 EC58PL02 8250 8500 8000 1321642 1321626 1321620 1321608 #2 34° .207 Blue .200 Brown . #2 36° EC65PL05 EC65PLE05 EC80PL0 1 #2 1.190 12.200 Red! White .24" 11.5° B-2 16:35 16:39 17:35 36S B-2 l Trail EC50PM04 7000 1321570 1.207 Blue .030" Driven Helix Angle & Location Chaincase Gearing StarLite Indy LitelGT Lite Deluxe Sport Sport Touring Super Sport EC25PS07 EC34-2PM02 10M Red 10 36S B-2 15:41 16:39 36S B-2 EC44-3PM01 EC44-3PM02 6800 7000 10 10AL Bushed 10AL Bushed 10AL Bushed 10 Bushed 10 Bushed 10MB Bushed 10MB Bushed 10MB Bushed 10M Bushed 10M Bushed 10M Bushed 10M Bushed 10MB Bushed 10 AL Bushed 10-62 Bushed 1.00" 12.207 Blue .TORQUE-O-MATIC DRIVE Data 1995 PRODUCTION SETUP Machine Model Engine Model Operating RPM ± 200 6300 7000 Production Clutch Part No.207 Gold .00" 12.

5° #B-2 36. to 6000 Ft. Machine Model StarLite Lite GT Lite Lite Deluxe Sport Sport Touring Super Sport 10 Bushed 10AL Bushed 10 Bushed 10 Bushed 10M White Bushed 10M White Bushed 10MW Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10 Bushed 10 Bushed 10-60 Bushed Red! White Red! White Red! White Red! White Blue Shift Weight 10M Red 10M Blue 10 Clutch Spring Red! White Gold Driven Helix 36.5° #B-2 36S #B-2 Red! White 16:35 16:39 Gold 36S #B-2 16:35 16:39 16:35 16:39 36S #B-2 36 ° #2 36 ° #2 36 ° #2 34 ° #2 34 ° #2 34° #2 36° #2 36° #2 36° #2 34° #2 34° #2 36 ° #2 36° #2 34° #2 17:35 10AL Bushed 10 Bushed 10M Blue Bushed 10M Bushed 10M Red Bushed 10M White Bushed 10MR Bushed 10M Blue Bushed 10M Blue Bushed 10M Blue Bushed 10M White Bushed 10M White Bushed 10M Blue Bushed 10M Blue Bushed 10-58 Bushed Gold 36S #B-2 36° #2 36° #2 36° #2 34° #2 34° #2 34° #2 36° #2 36° #2 36° #3 34° #2 34° #2 34 °#2 or 36° #3 34°#2 or 36° #3 34° #2 17:35 10M Blue Bushed or 10 Bushed 10M Blue Bushed 10M White Bushed 10M Blue Bushed 10M Red Bushed 10M Red Bushed 10MR Bushed 10M White Bushed or 10M Red Bushed 10M White Bushed or 10M Red Bushed 10M White Bushed or 10M Red Bushed 10M Red Bushed Red! White Gold Red! White Red! White Red/ White Blue 36S #B-2 36° #2 36° #2 36° #2 34 ° #2 34° #2 34° #2 36° #2 36° #2 36° #3 34° #2 34° #2 34°#2 or 36 ° #3 34°#2 or 36° #3 34° #2 17:35 Trail Trail Deluxe WideTrak LX 21:39 20:39 19:41 Red! White Red! White Red! White Blue 21:39 20:39 19:41 21:39 20:39 19:41 WideTrak GT 440 Indy 440 SKS 440XCR 19:41 19:41 19:41 21:39 20:39 21:39 20:39 21 :39 20:39 Blue 21 :39 Blue 21:39 Blue 21:39 600XCR Indy 500 Blue Gold 21 :39 21:39 Blue Blue 21:39 21:39 Blue Blue 21 :39 21:39 Classic 500 EFI Gold 21:39 Blue 21:39 Blue 21:39 500 EFI SKS Gold 20:39 Blue 20:39 Blue 20:39 XLTIXLT SP XLT SKS XLT Touring Gold 21:39 20:39 Blue 21:39 20:39 Blue 21:39 20:39 Gold 20:39 Blue 20:39 10MRed Bushed 10M White Bushed 10M White Bushed 10 Bushed or 10ALBushed Blue 20:39 RXL Blue 20:35 Blue 20:35 Blue 20:35 RXL Touring Blue 21:39 Blue 21:39 Blue 21:39 Storm Storm SKS Blue 23:37 20:35 Blue 23:37 20:35 Blue 23:37 20:35 8/94 7. Clutch Spring Gold Gold Driven Helix 36.26 .TORQUE-O-MATIC DRIVE Data 1995 HIGH ELEVATION RECOMMENDATIONS 3000 Ft. to 9000 Ft. Clutch Spring Blue Blue Gold Blue Gold Driven Helix Chaincase Gearing 15:41 16:39 36S #B-2 36. to 12000 Ft.5° #B-2 36S #B-2 36.5° #B-2 Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White 10 6000 Ft.5° #B-2 Chaincase Gearing 15:41 16:39 Shift Weight 10M Red 10M White or 10M Red 10 or 10M Blue 9000 Ft.

Clutch (Brown) 3 Pin. 8.Drive Clutch Basic Bolt Washer. Sleeve 1 Bearing. IRetl Part No. 1321457 1321622 13. 7512266 18. Drive Clutch Basic Bolt Washer.. 4.. 1321523 7512265 7552804 3576510 7041061 5020422 5430728 5430945 1321457 I Qty· 1Description Asm. 4.020mm Bearing. Bearing Spring. . ** 16. 7. . 3576504 12. Guide 1 Nut. Multilube 1 6 6 1 1 1 3 3 3 3 7. 5630272 13.. 5210754 5210753 5210752 11.~ _____________ y 1./ 5. Sleeve (Trail w/EC50PM) 1 Insert. 6. Guide AR Spacer. 3. Cover Spring. Split Lock (6mm) Cover.) & 2. 5. . V . ** 7512265 7552801 3576510 7710417 ** 5020436 5020422* 5410374 5430728 5430728 5020425 5430945 • All other P-85 BasIc except 500 90/91 12. Weight (10) Bolt. Flex Lac 6. 7541906 17. . Multilube 3 Asm. Guide 6 Washer.020mm 3 WeighUBushing 3 Nut 3 Bolt 1 Bearing. Roller & Bushing (Storm Only) 3 Button.050mm Spacer. 5430768 14. 3576502 3576503 19. Shoulder Nut.TORQUE-O-MATIC DRIVE Drive Clutch Service Parts c ~___________ . I Ref I Part No 12. Moveable 1/2" Shift. Retaining. 13. Moveable 1. . . -' ) ~--------------~y ----------------~ 1.050mm AR Spacer. 3. 7541906 I Qty·1 Description AR AR AR 1 2 3 3 Spacer. 3. 7. ~ . Roller Seal Button. 11 . Guide 6~ Button. 10. 5210754 5210753 5210752 15. 9. I Qty·1 Description Asm.. 5010188 ~) I Qty·1 Description 3 Asm. \ \ ' . . 8. Roller and Bushing 1 6 6 1 1 I Ref I Part No 10. 7. Clutch Pin.032mm AR Spacer._8_ IRetl Part No. ~ 9. Roller Pin. .. Roller 6 Button. 2. Spring Lock Cover. 5. 7512266 14. Jam 6 Washer.27 8/94 . Roller & Bushing 3 Asm. 1.032mm Spacer. 9. 2. Bearing Ring.

5 ± 1 PN 5630224 8 A Gram Weight: 43 ± 1 Gram Weight: 47.TORQUE-O-MATIC DRIVE Drive Clutch Weight Identification .5± 1 PN 5630094 01 01 Gram Weight: 48.(8 Modified) Gram Weight: 41 .5 ± 1 PN 5630109 G .5 ± 1 PN 5630227 7.28 .5 ± 1 PN 5630063 B A AlP Gram Weight: 47.Actual Size u Gram Weight: 34 ± 1 PN 5630107 y Gram Weight: 35 ± 1 PN 5630139 W Gram Weight: 37.Weight: 53 ± 1 PN 5630174 03 Gram Weight: 32.5 ± 1 PN 5630084 PN 5630080 I' 02 02 Gram Weight: 49 ± 1 PN 5630225 8/94 03 o Gram Weight: 51 PN 5610088 o Gram .

5 ± 1 PN 5630229 M1 (Modified) Gram Weight: 46.TORQUE-O-MATIC DRIVE Drive Clutch Weight Identification .5 ± 1 Gram Weight: 51 .5 ± 1 PN 5630245 PN 5630249 10 Gram Weight: 51 .5 ± 1 PN 5630234 06 Gram Weight: 50 ± 1 PN 5630243 07 07 Gram Weight: 52 ± 1 PN 5630244 08 08 09 Gram Weight: 47.Actual Size o o 04 04 Gram Weight: 57.5± 1 PN 5630272 8/94 7.29 .5 ± 1 PN 5630302 K1 Gram Weight: 39 ± 1 PN 5630144 P1 Gram Weight: 42 ± 1 PN 5630089 J1 Gram Weight: 44 ± 1 PN 5630065 05 Gram Weight: 53.0 ± 1 PN 563030 1 N1 (Modified) Gram Weight: 51.

5 ± 1 PN 1321526 10M 10M B 10M-W Bushed Gram Weight: 46 ± 1 PN 1321527 ·8/94 10M Bushed Gram Weight: 49.TORQUE-O-MATIC DRIVE Drive Clutch Weight Identification .0 ± 1 PN 5630274 PN 5630286 10M Gram Weight: 49.5 ± 1 PN 5630273 10M Blue Gram Weight: 47.30 .5 ± 1 Gram Weight: 55.5± 1 PN 1321529 1OM Red Bushed Gram Weight: 44 ± 1 PN 1321530 7.5 ± 1 PN 1321528 10M Blue Bushed Gram Weight: 47.5 ± 1 PN 5630324 10M Red Gram Weight: 44 ± 1 PN 5630325 10MIW Gram Weight: 46 ± 1 PN 5630369 10AlL Gram Weight: 53 ± 1 PN 5630368 10 Bushed Gram Weight: 51.Actual Size 15 10A Gram Weight: 55.

TORQUE-O-MATIC DRIVE Drive Clutch Weight Identification .31 8/94 . Gram Weight: 58 PN 1321588 10A Bushed Gram Weight: 55 PN 1321589 7.Actual Size 1O -AL Bushed Gram Weight: 53 ± 1 PN 1321531 10-66 Bushed Gram Weight: 66 PN 1321584 10-64 Bushed Gram Weight: 64 PN 1321585 10-62 Bushed Gram Weight: 62 PN 1321586 10-60 Bushed Gram Weight: 60 PN 132 1587 10-58 Bushed .

..~- ! .. 260 1 P-90 TRAVEL --4~---I~~..32 .I ~ 240 -.Blue/Blue-Gold 7041080 _ Silver/Gold 704 1286 . ~ . etc... . ... 280 :... I ! . 220 + · . DRIVE CLUTCH SPRING COMPRESSION RATE CHART 300 --. ~~~"~~--'r . 1 P-85TRAVEL---4 .-----~. 160 -1 t ~ o u... heavy loads. =.... mountainous terrain. _ _ . w o a: .....i ...r TORQUE-O-MATIC DRIVE Drive Clutch Spring Rates The following chart will aid in the setup and balance of engine RPM power curves for special converter tuning requirements such ~s high operating altitude. . - ---...-------~----~~'~ ! ~j . . -f----. I ! 1 I ? en c z ~ .. COMPRESSED SPRING LENGTH (INCHES) 8/94 7...- "\--_ .' 200 -1 I .

192" .TORQUE-O-MATIC DRIVE Drive Clutch Spring Data PART NUMBER COLOR CODE WIRE DIAMETER FREE LENGTH +/.59" 3.207" . 7.05" 3.37" 3.25" 3.37" 3.177" . Due to the severe stress the spring is subject to during operation. it should always be inspected and checked for tolerance limits during any clutch operation diagnosis or repair.192" .21 8" 4.33 8/94 .200" .77" 2.92" 3. Refer to the chart above for specific free length measurements and tolerances.192" .50" 3. Included in these are converter alignment.196" .207" .140" . Maximum efficiency of the variable speed drive system is dependent upon many factors.05" . Replacement is required..208" . One of the most critical and easily serviced parts is th e drive clutch spring. measure its free length from its outer coil surfaces as shown.168" . 12" 4.69" 3.38" 4.177" . CAUTION: Never shim a drive clutch spring to increase its compression rate. In addition to proper free length.1 77" . and internal condition of the drive and driven clutch components. belt tension. the spring coils should be parallel to one another when placed on a flat surface.1 25" 7041021 7041022 7041063 7041062 7041065 7041060 7041080 7041083 7041102 7041061 7041132 7041168 7041148 7041150 7041286 Clear Black Purple Silver Pink Orange Blue/Gold Red Yellow Brown White Green Gold Red/White Silver/Gold .157" . With the spring resting on a flat surface.25" 4. This may result in complete stacking of the coils and subsequent clutch cover failure.06" 2. Distortion of the spring indicates stress fatigue.92" 3.

If the belt is too long or the center distance too short. In order to achieve maximum efficiency from the converter. the machine may creep when the engine idles. In addition. This is due to the belt rising too high in the drive clutch sheaves upon engagement. causing damage to the internal face of the drive belt. o 8/94 7. resulting in performance loss. the ratio will again be incorrect. the initial starting ratio will be too low. the drive belt must be adjusted properly for tension and clutch offset. If the drive belt is too short or the center distance too long.34 .TORQUE-O-MATIC DRIVE Drive Belt Adjustments The drive belt is an important component of the converter system. Critical dimensions and construction have been provided for at the time of manufacture.

TORQUE-O-MATIC DRIVE Drive Belt Adjustments c Aluminum Driven Clutch Ideal belt deflection is 1 1/4/1 (3. Turn cam counterclockwise to reduce distance between sheaves. May use optional. 3. Straight Edge 1 1/4/1 (3.048/1) washer PN 7555899 7. thinner (. Measure belt deflection with both clutches at rest and in their full neutral position. this will result in an improper measurement. Aluminum Driven Clutch with Outer Cam Adjuster C Belt deflection can be adjusted without removing the clutch from the jackshaft. Loosen three bolts on adjustment cam. Place a straight edge on the belt and apply downward pressure while measuring at the point shown. 1.2 cm) IMPORTANT NOTE: Do not apply excessive pressure to force the belt into the driven sheaves.35 8/94 . (1 .38 kg/m). add or delete thrust washers. Ibs. 2. 4. To change belt deflection. NOTE: One thrust washer should always be left between the driven clutch sheaves.2 cm). Torque bolts to 10ft. Pull belt into driven clutch to slightly open sheaves.

21/32" Offset All models with P90 aluminum driven clutch 5/8" Offset '. .. 21/32" Offset Use the proper clutch alignment tool to check clutch offset. ' '. '. NOTE: The drive belt must be removed for this measurement.' All models with P8S aluminum driven clutch NOTE: Up to 1/8" air gap allowed on new machines Offset Alignment Tool ) 8/94 7..I. 5/8" Offset PN 2870914 P90 Clutches. When the clutches are properly aligned. The motor mounts on some models are slotted to allow for installation of washers behind the driven clutch to achieve correct offset.36 .TORQUE-O-MATIC DRIVE Clutch Alignment Clutch Alignment Tools: PN 2870426 P8S Clutches. the tool will contact all sheave surfaces equally.

Cover 1 Spring. Guide 6 Washer. Drive Clutch Basic 34 (Less 6 & 14) 6 Bolt 6 Washer. Retaining. 8. 5. 1 Cover. 1N i. 7541906 17. 3. 1321531 15. Clutch (Blue) 3 Pin. 12. Roller & Bushing 3 Asm.032mm Spacer. 1..050mm Spacer. 5210754 5210753 5210752 14. o IRef. 3576502 3576503 18. Weight/Bushing (10A-L) Pin. 4. Multilube 3 Asm. 5020425 13.1 Part No. 7515105 16.1 Part No. 16. Sleeve (Trail w/EC50PM) Insert. 2.-- L ~~ 9. Sleeve Bearing. 10. Bearing 1 Ring. .020mm Asm. Weight Nut Bearing.Shim. 11. Spring Lock . . 5010188 I Qty·1 Description 1 AR AR AR 3 3 3 1 1 1 Nut. 7. 6.. 1321551 7512265 7552801 3576510 7710417 7041080 5020422 2200387 5430445 5430945 1321457 1321622 I Qty·1 Description 1 Asm. Roller 1 Kit .37 8/94 . 12. Roller & Bushing (Storm Only) I Ref. II '-~ !~] r ~ 15. .. 1. 9..TORQUE-O-MATIC DRIVE P-85 Drive Clutch 2. Jam Spacer. Drive Clutch 6 Button. Moveable 7.

Prior to reinstalling drive clutch to engine.--~-. 2. Clean taper by manually rotating clutch clockwise. While all drive clutches may look alike. These numbers are the last three digits of that clutch part number. refer to the three numbers behind date code on moveable sheave. CAUTION: Never use an air impact wrench for installing or removing a drive clutch . Remove drive clutch retaining bolt and install puller PN 2870506 into clutch.38 8/94 . Ibs. each bears a different number. Torque retaining bolt to 40-45 ft. or strike t-bar with a hammer until clutch is removed . Position clutch on engine crankshaft. Install strap wrench PN 2870336 to clutch cover. Place reamer in a vise and lubricate with cutting oil. bore taper should be trued by usi ng tapered reamer PN 2870576. Used up to 1993 J 7. It will loosen the spider torque value and could cause engine crankshaft damage. 3. For easy identification.TORQUE-O-MATIC DRIVE Drive Clutch Identification and Removal 1. --. Install retain ing bushing and bolt using strap wrench PN 2870336 to hold clutch. This number indicates internal clutch component variation for individual engines. Tighten puller with a wrench.

5.TORQUE-O-MATIC DRIVE Drive Clutch Disassembly and Inspection c 1. Remember that there is spring tension on the cover.39 8/94 . Install drive clutch into clutch holding fixture PN 2870461. 2. On models equipped with a spider jam nut. Carefully remove cover attachi ng screws. Count the number of spacer washers installed beneath the spider. 3. Install spider removal tool PN 2870341 and remove spider. 4. 7. install jam nut tool PN 2870338 and remove jam nut.

bushings.40 . thrust washers.TORQUE-O-MATIC DRIVE Drive Clutch Disassembly and Inspection 10. drive out the roller pin. remove drive clutch fly weights. USing a pin punch. Place spider on a vise. 13. Remove spider buttons using button removal tool PN 2870985. 11. Using a 1/8" Allen wrench and 3/8" combination wrench. Inspect all rollers. 12. 8/94 7. and roller pins.

driving a pin in about . 9.TORQUE-O-MATIC DRIVE Spider Assembly c C 1. The roller bushing could be damaged causing premature wear and roller failure. Determine how many shims are to be used. Also use care to make sure the roller remains aligned when the pin is driven through. 7. Start a replacement roller on each leg. 5. 3.002". 7. Aluminum burrs could pass through into the roller bushing causing it to bind and stick. CAUTION: Use care to start the pin straight. Install one washer onto the pin. Install spider buttons using a soft face hammer. 4.25-. including .100"-. Measure the dimension between towers at the lower half of the towers as shown. 6. and . Place spider on a vise anvil and drive the roller pin through to the second land of the spider. NOTE: Shim Kit PN 2200387 contains an assortment of shims.125" (. Place a few drops of Polaris clutch and cable lube (PN 287051 0) onto the roller bushing.32 cm) beyond the fi rst land of the spider leg (A) . Install service tool as shown in photo 2. 2.005".010". Place a second washer on the other side of the roller. TIP: This enables you to locate the first washer and align the roller until the pin is flush with the second land. 8. Place roller on pin as it protrudes from first land.41 8/94 . .

Add shims beneath spider button to obtain . Place the correct number of spacer washers beneath the spider. 11. 12. 8/94 7. Assemble clutch making sure "X" marks are aligned to achieve proper balance. 13.42 . Record width of spider buttons on each leg.05 mm) clearance between button and tower when assembled.TORQUE-O-MATIC DRIVE Spider Assembly 10.002" (.

7.6 kg/m) . Torque jam nut to 235 ft. (27. Torque spider to 200 ft.) 28. (32. Ibs.43 kg/m). Torque cover screws to 90 inch Ibs.43 "" 8/94 . Assembly c c 27. (Applies to either P8S or P90 models.) 29. Install spring and cover.TORQUE-O-MATIC DRIVE SpiCIer. Ibs. (Select P8S rifodels only.

050" . Spider Shimming 1.020" requ ires disassembly and re-shimming of the spider.5 mm) as possible without creating a drag on the belt when positioned around the hub at the bottom of the sheaves.032. NOTE: Any clearance over . Place drive clutch on holding fixture and unscrew spider.020" (.020" 8/94 7.375" +/.44 .TORQUE-O-MATIC DRIVE Spider Indexing 1. The following washers are available for fine tuning: PN 5210754 PN 5210753 PN 5210752 . Mark spider. 2. Adjust spider washer pack to achieve desired belt to sheave clearance as described above. Remove drive clutch from engine and remove drive clutch cover and spring. moveable sheave. New belt measurement width specification is 1.032" . 2. Measure total belt to sheave clearance with a feeler gauge as shown in photo 2. The distance between the belt and moveable sheave should be as close to . 1. cover. This distance controls the starting ratio (lowest starting ratio is most preferable) and the position of the clutch weight to engine RPM. and stationary sheave in line as shown in photo 1. Fine Tuning The distance between the belt and the moveable sheave on the drive clutch is very important.

<[ 7. For example: " .re-index spider clockwise 1/3 turn .050" or .064" washers removed re-index clockwise 2/3 turn NOTE: Alignment marks should be within 1" (2. .re-index spider clockwise 1/3 turn Two .050" or . Re-indexing the spider 1/3 turn clockwise. . will . allow the realignment of the moveable and stationary sheaves as preViously marked. The spider must be rotated clockwise into the moveable sheave to maintain relative clutch balance after reassembly. or 1 leg.064" washer removed .020" or .5 cm) after final assembly and torquing. Install spider washer(s) and spider.TORQUE-O-MATIC DRIVE Spider Indexing c 3.45 8/94 . • • • .032" washer removed .

Remove snap ring and washer. (1 . 6.66 kg/m).46 .TORQUE-Q-MATIC DRIVE Aluminum Driven Clutch Service . 5. causing premature bearing failure. When driven offset is properly adjusted. Torque bolt to 12 ft. the jackshaft bearings could be side loaded. Removal of a thrust washer increa:ses neutral belt tension. Inspect ramp buttons and bushing for wear. Polish helix with a fine emery cloth to remove any sharp edges which may cause sticking. 3. It should slide freely without binding. Reassemble stationary and moveable sheaves.P85 1. NOTE: Addition or subtraction of these washers affects clutch alignment. 2. Install helix into bushing. Without a slight free float. 8/94 7. the washers (A) (PN 7555734) are used to adjust for free float on drive. 4. These washers may be used to adjust the effective belt tension measurements as described earlier. Note condition of moveable sheave bushing. Clean all parts. Note the placement of the two thrust washers shown. 7. Ibs.

The normal rate of change between helix angle steps is 250 RPM under full throttle.4 spring position. The higher spring tension will slow the upshift. such as slow trail riding. Polaris has several helix angles available for the aluminum drive clutch. Using a good quality force gauge. NOTE: This range may not be desirable under some riding conditions. On all models the production helix spring hole location is No. Tension the spring 1/3 turn. installing spring into helix. Refer to the chart below for specific angle effects and identification. To obtain this range.P-85 Helix Angles And Effects The driven clutch helix was selected for overall performance in relation to the other driven system components. we recommend trying a helix change before changing other components. Reassemble clutch. With drive belt removed. A desirable range for the Polaris OEM spring is from 9 to 13 Ibs.1 to No. Helix 34° PN 5630168 36° PN 5630185 42° . NOTE: Increasing spring tension increases engine RPM. decreasing fuel economy.TORQUE-O-MATIC DRIVE Aluminum Driven Clutch Service . 9. o et D NOTE: Always Install Snap Ring with Chamfer Towards Helix 7. Install helix key. RPM changes may not be evident if other drive or driven clutch components are substandard. insert a pin punch or drill bit into a balance hole on the moveable she·ave. In fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift.36° . This is approximately the same result as in going from the No.2.3 position. thrust washer and snap ring. record poundage at the point where the sheave just begins to break away. 8. it may be necessary to move the spring to the No.47 8/94 .34 ° Combination Increasing Decreasing N/A RPM Effect Identification Number 34 marked on back side of helix Number 36 marked on back side of helix Identification T-1 marked on back side of helix c PN 5131013 The helix spring should always be adjusted within its limits before a helix change is performed.

8/94 7.2 A . Example: Spring/ Position Helix B - Moveable Sheave 1 Spring Tension B A - 2 1 B-3 A .3 Soft Production settings are usually B2 The driven clutch ramp buttons are secured by Torx screws.48 . The tightest spring tension will raise engine RPMs during clutch upshift and allow quicker downshift when pulling or negotiating a hill. NOTE: Preload on the driven spring from any of the various spring positions is 1/3 turn preload tension (counterclockwise). The lighter tension positions will tend to have a slower downshift and a harder upshift.TORQUE-o-MATIC DRIVE Aluminum Driven Clutch Service . After rebuilding. The ramp buttons should be replaced when worn. the driven clutch can be reassembled. The driven clutch helix/moveable assembly has several different spring locations wh ich affect clutch shifting and RPMs.P90 Used to adju st belt tension. One must always be installed.

adjust or replace -Measurement should be taken 12" (30. -Inspect/replace -Install new buttons or shim out existing buttons -I nspect/replace -Bearing failure/ chaincase. Engine bogs after engagement.Excessive belt to sheave clearance with new belt (high performance version without detent shift weight) Drive belt turn over -Wrong belt for application -Clutch alignment out of spec -Engine mount broken or loose -Replace -Perform belt to sheave clearance adjustment with shim washers beneath spider .Replace -Adjust alignment offset -Inspect. sprocket teeth broken -Inspect/replace TroubleshQoting REMEDY c Noise in drive system -Driven clutch sheaves have excessive runout. jackshaft or front drive shaft -Inspect/adjust or replace -Drive chain loose or worn. are bent or damaged -Broken drive clutch components -Excessive drive clutch button .49 8/94 .015" (.6 mm). -Worn belt -Excessive belt deflection -Spider roller position remaining in detent -Add spider shim washers -Add driven washers -Reduce gear ratio (chaincase models) -Replace -Subtract driven clutch washers 7. Maximum allowable tolerance is .5 cm) in from outer circumference on sheave face.tower clearance -Driven clutch bushing worn excessively or spring -I nspect/replace broken -Drive belt surface flat spots DETENT SHIFT WEIGHTS Over rev during initial acceleration or during heavy pulling at low ground speeds.TORQUE-O-MATIC DRIVE SITUATION Harsh drive clutch engagement PROBABLE CAUSE -Drive belt worn too narrow .

clean and inspect driven clutch. -Disassemble. belt slippage Erratic engine operating RPM during acceleration or load variations -Drive clutch binding -Drive clutch shift weights incorrect for application (too light) -Drive clutch binding -Driven clutch binding 8/94 7. Reassemble without the spring to further determine probable cause.50 . refer to proper installation location -Clean clutches. reassemble clutch without spring to determine problem area -Driven clutch malfunction -Replace ramp buttons -Inspect moveable sheave for excessive bushing clearance/ replace Engine RPM above specified operating range -Incorrect drive clutch spring (too high spring rate) -Install correct recommended spring -Install correct recommended shift weights -Disassemble and clean clutch. although engine is in properly tuned PROBABLE CAUSE -Wrong or broken drive clutch spring REMEDY -Replace with recommended spring -Install correct shift weight kit to match engine application -Replace spring.TORQUE-O-MATIC DRIVE Troubleshooting SITUATION Engine RPM below specified operating range. inspecting shift weights and buttons. noting worn sheave bushing and ramp buttons and helix spring location -Drive clutch shift weight too heavy -Driven clutch spring broken or installed in wrong helix location (aluminum clutch) -Drive belt too long -Converter sheaves greasy. install new belt -Install new belt and/or adjust belt tension -Disassemble drive clutch. inspect shift weights for wear and free operation -Clean and polish stationary shaft hub.

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