Drive Clutch Disassembly - Polaris 600 RUSH 2010 Manual

PVT System

Drive Clutch Disassembly

SPIDER BUTTON
COVER
COVER BEARING
RETAINER
CAUTION
Wear eye protection when servicing the drive clutch.
Sheaves must be marked to provide a reference point
for clutch balance and spider indexing. If the sheaves
are not marked and the spider washers are changed or
misplaced, the clutch may be out of balance and
damage to the clutch may result.
WARNING
Clutch spring is under extreme tension, use caution and
wear eye protection when disassembling the clutch.
1. In a straight line, mark/etch the sheaves and the cover
with a black marker or a scribe.
2. Place the drive clutch in the clutch compression tool
(PN 8700220).
3. Compress the clutch in the compression tool, then
secure the chain.
4. Evenly remove the cover fasteners. The cover
bushing may be damaged if the cover is side-loaded
or mis-aligned.
5. Carefully remove the tension from the compression
tool.
6. Remove the cover and inspect the cover bushing.
Replace if damaged or worn.
NOTE: Replace the cover bushing if the inside
diameter is over 1.40 (28.95mm)
7. Remove the spring.
6.18
ROLLER
WASHER ROLLER PIN
SHIM
SPRING
JAM NUT
SPIDER
SPACERS
CLUTCH SPACER
WEIGHT
WEIGHT PIN
BEARING SLEEVE
MOVEABLE SHEAVE
8. Mount the drive clutch securely in a drive clutch
holding fixture (PN 2871358).
9. Remove the jam nut in a counterclockwise direction
(standard thread) using the drive clutch spider nut
socket (PN 2871358).
10. Install the spider removal tool (PN 2870341), and
remove the spider in a counterclockwise direction
(standard thread).
11. Measure the total thickness of the spacer washers
that are installed on top of the clutch spacer. Record
the thickness of these spacer washers.
12. Inspect both sheave surfaces for wear or damage.
13. Inspect the moveable sheave bushing for wear or
damage.
14. Remove all three drive clutch weights.
15. Inspect each weight. The surface should be smooth,
with no waves or galling. Place pin inside weight to
check flyweight bushing and pin surface for wear by
rocking the weight back and forth.
16. Inspect all the rollers, bushings and roller pins by
pulling a flat metal rod across the roller.
17. Roller can also be inspected by rolling with a finger to
feel for flat spots, roughness, or loose bushing.
NOTE: The flyweight bushing is not replaceable. If
flyweight bushing is damaged, the flyweight, pin and
nut will need to be replaced.
18. Inspect to see if the roller and bushing are separating.
19. Bushing must fit tightly in roller.
20. Replace roller and pin if roller fails to roll smoothly (no
flat spots) or if the bushing is loose or worn.
MOVEABLE INSERT
STATIONARY SHEAVE