Polaris 2005 SPORTSMAN 500 Servise Manual page 180

CLUTCHING
DRIVEN DISASSEMBLY/ASSEMBLY
1. Remove driven clutch from the transmission input
shaft. Do not attempt disassembly of the driven
clutch from the outside snap ring. The driven
clutch must be disassembled from the helix side.
2. It is important to mark the position of the shaft,
stop plate, and sheave before disassembly. Mark
the helix and inside sheave also. This will aid in
reassembly.
Mark Components Before Disassembly
Mark Components Before Disassembly
3. Place the driven assembly into the clutch holder.
Push helix inward. Remove snap ring (A) and
washer (B). NOTE: The spring is a compression
6.28
spring only and has no torsional wind.
A
B
NOTE: Rotating the moveable sheave so that the
rollers are not in contact with either helix ramp
surfaces will lessen the effort needed to push the helix
inward.
4. Remove helix (C), spring (D), and spring seat
washer (E) and inspect for wear or damage.
Replace if worn.
NOTE: Note the keyed spline on the shaft and
helix for reassembly. The keyed shaft ensure
proper alignment of the helix to the shaft.
C
D