Polaris SPORTSMAN 600 2003 Service Manual page 152

CLUTCH
ONE-WAY CLUTCH INSPECTION (DRIVE
CLUTCH) CONT'D
3. Inspect surface of shaft for pitting, grooves, or
damage. Measure the outside diameter and
compare to specifications. Replace the drive
clutch assembly if shaft is worn or damaged.
Shaft Diameter
Standard: 1.3745 - 1.375
Service Limit: 1.3730
4. Remove 2 1/2 PTFE washer from shaft. Visually
inspect the washer for damage. Measure the
thickness and compare to specification. Replace
if worn or damaged.
PTFE Washer Thickness
Standard: .030 (.76mm)
Service Limit: .025 (.64mm)
MOVEABLE SHEAVE
BUSHING INSPECTION
1. Inspect the Teflont coating on the moveable
sheave bushing. Inspect BOTH sheaves for signs
of wear, grooving or cracking. Clean surfaces with
a 3Mt pad if needed
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more
brass than Teflont is visible on the
bushing. Refer to bushing replacement
in this chapter.
6.18
EBS DRIVEN CLUTCH
DISASSEMBLY/INSPECTION -
CAUTION: The driven
disassembled from the helix end to lessen the
chance of damage to seals in the one-way clutch.
Review all information below before proceeding.
ONE-WAY CLUTCH
PRELIMINARY INSPECTION
(DRIVEN)
1. With drive belt removed and transmission in gear,
hold the inner sheave and rotate the outer sheave
of the driven clutch in a counterclockwise
direction as shown at right. The sheave should
rotate with only a slight amount of drag. There
should not be any binding or rough spots.
clutch must be
Move Freely