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238
ber
of
shim(.,)
prior to
installing the
driven pulley.
Iustallation
(All Models)
NOTE
Make sure
the
same
number
of
shimts),
as
noted
(luring
removal,
are
ill
place
011
the transmission input
shaft.
I
A.
On 1996
-1998 models, install
the shim(s )( Fig-
ure
90
) and on
so
me
mod els. the bushin g o
nto
the
transmission shaft.
IB.
On 1999-on
model s. install
the
sh
im(s) (Figu re
92
) and wa
sher
(Fig u re
91) o
nto
the
transmissio n
shaft.
2. Clean the splines on the
transmission
input shaft
and apply
a light film
of
low-temperat ure grease to
the splines
.
3.
A
lign the master
splines
of the
pul
ley
assembl
y
wi
th
the
input
sha n
a
nd slide
the
dri
ven pu
lley onto
the
shaft.
Push
it
on until
it
bo
tto
ms.
4
.
Pos ition
the domed
washe r (A,
Figu re
93)
as
show n
so
it
can
accept
the
smalle
r
lockwasher
(B.
Figure 93)
.
5.
Insta
ll
the mou nting bolt (Figure
88
) and tight
en
to the
torqu e
speci
fication listed
in Ta
b le
5.
6.
Check the
pulley
offset
as de
sc rib ed
ill
this
chap-
ter.
7.
Install
the
drive be
lt
(A
.
Fig
u re
87)
as described
in
this chapter.
8.
Check the driv
e belt deflection as described
in
this
chapter.
9.
Check the
o
uter cover seals. then
install as de-
scribed in
Chapte r
Three.
Disassembly (1996-1998 Models)
Re fer to
Figure 94
.
II
~IRNING
The
driven
pulley
is
under spring
pressure.
Attempting
to
disa ssemble
o
r
reassemble
the
dri ven pulley with-
alit
the lise of the
specifie d
VST spe-
cial tool
s may ca
use
pe
rso nal
injur y:
If
the necessary tools are not a
vail-
able.
ha
ve
the
service
perform ed by a
Polaris dealership
or
repair
facility
with
the proper
equipment.
C
HA P TE R EIG HT
®
NO TE
Inspect the
dri
ve pulley
assembly
be-
fore
beginning
to disassemble
it
to de-
termine
if
any
of
the
major
co
mp onents
requires replacem ent
.
In-
stall a
l1el1 ' complete
drive
clutch
as-
sembly
iF
the C
OI'el; Fred sheave,
sp ide
r
or
mo
vable
sheave
is
da
maged,
Ne
ver
replace
pa
rts with
used p
arts
.Ii'OlI1
anoth er
assembly.
I.
Before disassemb ling
the
driven
pulley, locate
the
end of
the
spring in
one
of
the two holes
in
helix
cam.
Mark
the
hole for identificati on of
or
iginal
sel-
ling,
WARNING
Wear eye
protection
and hold the
helix
cam
securely
when
removing
the
snap
ring in
Step
2.
2.
Set
the
driven pulley on
the
wo
rkbench
with the
fixed
sheave facing do wn.
push
the helix cam (A
,
Figu re
95)
down and remove the snap ring (B
.
Fil:-
ure
95).
Slow ly release
the heli x.
allowing it to
co me
up
and
tum.
3. Carefully
remove the hel ix cam from
the
spri
ng.
but leave
the
spring located in
the moveable
sheave.
4. Note and mark the location of
the end
of the
spring in the movab
le
sheave,
then
remove the
spring, The suggested initial setting for a new
spring is listed
in Table 4
.
NOTE
The
sp acer
washers located
between
the
movable
and
fixed
shea ves are
used
to
adjust belt
deflection.
Do
110t
lose o
r
damag e these
sp acer
washers .
A
t lea
st
on
e
sp acer
must always be lo-
ca ted
between the
sheaves.
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Troubleshooting
