Clutch Assembly - Polaris Ranger 500 2x4 2007 Service Manual

CLUTCHING
4. Turn clutch cover and barrel together counterclockwise on
puller rod until bushing is seated.
5. Remove nut from puller rod and take installation tool and
clutch cover off the rod.

Clutch Assembly

It is important that the same number and thickness of washers
are reinstalled beneath the spider during assembly. The
Teflon™ bushings are self-lubricating. Do not apply oil or
grease to the bushings
Reassemble the drive clutch in the following sequence. Be sure
the "X", or the marks that were made earlier are aligned during
each phase of assembly
1. Install moveable sheave onto fixed sheave.
2. Install spider spacers. Use same quantity and thickness as
were removed.
6.18
Spacer washers
3. Compress spider buttons for each tower and install spider,
making sure that "X", or the marks that were made earlier,
on spider aligns with "X", or the marks that were made
earlier, in moveable sheave.
4. Torque spider to specification using the holding fixture and
spider tool. Torque with smooth motion to avoid damage
to the stationary sheave. Refer to Page 6.2 for torque
specification.
Be sure the spider spacer washers are fully
seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the
spider will help position the washers.
5. Install shift weights using new lock nuts on the bolts.
Nut on trailing side
6. Reinstall clutch spring.
7. Reinstall cover, aligning "X" mark with other marks.
8. Torque cover bolts evenly to specification.
Spider torque:
200 ft. lbs. (276 Nm)
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
CAUTION
Rotation