Drive Belt Removal/Inspection - Polaris SPORTSMAN 400 2003 Service Manual

CLUTCH
1 1/8² (28.5 mm)
Belt Deflection (Tension):
1 1/8² (2.9 cm) - 1 1/4² (3.2 cm)
If belt deflection is out of specification, adjust by
removing or adding shims between the driven clutch
sheaves.
G Remove shims to decrease belt
deflection
G Add shims to increase belt deflection
See Driven Clutch Disassembly/Inspection, Pages
6.19 - 6.20.
NOTE: At least one shim must remain between the
inner and outer sheave of the driven clutch. If proper
belt deflection cannot be obtained, measure drive belt
width, length, and center distance of drive and driven
clutch, outlined in this section; all have an effect on
belt deflection.
DRIVE BELT
REMOVAL/INSPECTION
1. Remove outer PVT cover as described in PVT
Disassembly.
2. Mark drive belt direction of rotation so that it can
be installed in the same direction.
Normally positioned so part numbers are easily
read.
3. To remove drive belt, apply brake, pull upward
and rearward on belt to open driven clutch
sheaves, pull out and down on belt to slip over the
driven clutch outer sheave.
6.14
Straight Edge
NOTE:
NOTE:When reinstalling the belt with the drive clutch
and driven clutch already removed follow these steps:
G
Install the driven clutch.
G Install the belt onto the driven clutch.
G Loop the drive clutch through the
belt.
G Install the drive clutch onto the
crankshaft.
4. Measure belt width and replace if worn.
Generally, belts should be replaced if clutches
can no longer be adjusted to provide proper belt
deflection.
G The top edges have been trimmed on
some drive belts. It will be necessary
to project the side profiles and
measure from corner to corner.
G
Place a straight edge on each side of
the drive belt.
G Place another straight edge on top of
belt.
G Measure the distance where the side
straight edges intersect the top, as