Polaris 1999 Sportsman 400 Service Manual page 231

CLUTCII/DRIVE BELT SYSTEM
2. Secure the dri ve pulley with a strap wren ch, then
loosen and remove the bo lt, lockw usher, thick
was hers and bushing (Figure 30).
3. Use the spec ial clut ch holding tool (A, Fi gure
31) or strap wrench to hold the dri ve pulley station-
ary du ring Step 4.
4. Install the special clutch
puller (8, Figure
31 )
through the pulley. Tighte n the puller screw to break
the drive pulley loose from the tape r
0 0
the
crankshaft.
NOTE
I] necessary, rap sharply on the head
ofthe puller to break the driv
e pulley
Fee fro m the crankshaft.
5. Pull the drive pulley (Fi gu re 32) stra ight off the
cranksha ft, then remove the pull er from the drive
pulley.
Disassembly
Prec ise balance is critical to the operation of the
drive pulley assembl y
and it
is critica l that the bal-
ance of the un it not be affecte d in a ny way. Th e
manufa cturer recommends tha t an authori zed Po-
225
laris deal er perform all serv ice work . If anoth er re-
pa ir faci lity is use d, make sure they are properly
equipped and ex perienced to service this type of
equipment. Removing the assembly and having a
repa ir facility pcrfonn the requ ired service can save
conside rable
expense.
Refer to Figure 33 for 1996- 1998 models and
Figure 34 for 1999-on models.
Inspect the drive pulley ass embly before begin-
ning any disassembly to determine if
the com po-
nents are
in
acceptable condition. Install
a
new
complete dri ve clutch asse mbly (Figure 35 and
Figure 36) if any individual component is dam -
aged . Never replace part s with similar used parts.
Two VST special too ls are requi red to per form
the follow ing procedures: the VST drive cl utch spi-
der remo va l tool, part No. 287034 1 (A, Figu re 37)
and the VS T clut ch hold ing fixture, part No.
287 1358 (8 ). Do not attempt the disassembly/as- . '
sembly pro cedure witho ut these tool s.
T he follow ing disassemb ly pro cedu re is provided
if the tools aod expertise are availab le.
1.
Before
disassemb ling, use
a felt-tip permanent
marker
to
make an alignment mark across each
clutch co mponent (F igu re 38 ). Refer to these marks
duri ng reassemb ly to ensure proper clut ch
align-
men t
and balance.
WARNING
The cover plate (A, Figure 39) is
spr ing-loaded. To pre vent itfromfly-
iug offduring removal, the cover plate
must be remov ed as described
ill
Step
2.
2. Loosen the cov er plate bo lls (B, Figur e 39 ) in
small increments in a crisscross pattern until all
spring tension
is
released. Remove
the cov er
plate,
bo lls and was hers.
3. Rem ove the spring (A, Figure 40) .
4. Remove the spider (8 , Figure 40) as follows:
CAUTION
The spider (B, Fig ure 40) is sec ured
tighr(v onto thefixed sheave with lock-
ing compo und. To prevent primm )'
shea ve damage. make sure the fixed
sheave is held securely when loosen-
ing the spider assembly as described
in this p rocedure.