Drive Belt Tension - Polaris SPORTSMAN 400 2003 Service Manual

DRIVE CLUTCH REASSEMBLY CONT'D
2. Install moveable sheave onto fixed sheave.
3. Install spider spacers. Use same quantity and
thickness as were removed.
4. 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 on the
moveable sheave.
5. Torque spider to specification using the holding
fixture and spider tool.
motion to avoid damage to the stationary sheave.
Refer to Page 6.3 for torque specification.
CAUTION:
Be sure the spider spacer washers are fully seated in
the recessed area of the spider. Any misalignment will
alter clutch balance. Inverting the clutch while initially
tightening the spider will help position the washers.
Spacer washers
6. Install limiter nut on top of spider using the Clutch
Spider Nut Socket (PN 2870338). Torque to 15 ft.
lbs. Reinstall shift weights using new lock nuts on
the bolts.
7. Reinstall clutch spring.
Nut on trailing side
Torque with smooth
Engine
Rotation
8. Reinstall cover, aligning "X" mark with other
marks. Torque cover bolts evenly to specification.
Spider Torque:
200 ft. lbs. (271 Nm)
Cover Screw Torque:
90 in. lbs. (10.4 Nm)

DRIVE BELT TENSION

(NON- -EBS)
NOTE:Belt tension is not adjustable on EBS
models.
NOTE:Pinch the sheaves lightly together with clamp
to prevent the belt from being pushed into the driven
sheave.
1. Place a straight edge on top of the belt between
drive and driven clutch.
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in illustration.
CLUTCH
6.13