Clutch Assembly - Polaris 2009 Sportsman XP 850 Service Manual

Clutch Assembly

NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
self-lubricating.
CAUTION
Do not apply oil or grease to the bushings.
Reassemble the drive clutch in the sequence provided below. 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.
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.
Spacer washers
CLUTCHING (PVT)
4. Torque the spider (counter-clockwise) to specification
using the holding fixture and spider tool. Torque with
smooth motion to avoid damage to the stationary sheave.
IMPORTANT: The clutch shaft has left-hand threads.
Be sure to turn the Spider Removal Tool in a counter-
clockwise direction to reinstall.
Spider Torque:
200 ft. lbs. (271 Nm)
CAUTION
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 the limiter spacer over the shaft and on top of spider.
6. Install shift weights using new lock nuts on the bolts.
Use new lock nuts
7. Reinstall clutch spring.
8. Reinstall cover, aligning "X" mark with other marks.
9. Torque cover bolts evenly to specification.
Cover Bolt Torque:
100 in. lbs. (11 Nm)
= T
= T
7.19
7