Clutch Alignment Inspection; Clutch Alignment Adjustment; Torque Stop Adjustment - Polaris 2003 Pro X Service Manual

Clutch Alignment Inspection

NOTE: Drive clutches are purposely misaligned slightly forward to compensate for the engine shifting on it's
mounts. Under load, the engine will pull back slightly so both clutches are in alignment.
1. After clutch offset has been verified, inspect alignment.
2. Install proper alignment tool, depending on type of clutch, as shown in Ill. 1 page.
3. There should be a .060 - .090 (1.5 - 2.25 mm) gap between front of driven clutch and tool, with the tool just
touching at the rear. Up to .125 (3.1 mm) gap is acceptable in the front on new machines.

Clutch Alignment Adjustment

1. Loosen all 4 engine mounting bolts.
2. Adjust engine torque stop until clutches are in proper alignment.
3. Tighten engine mounts securely.
4. Recheck both clutch offset and alignment.
5. Verify proper torque stop adjustment.

Torque Stop Adjustment

NOTE: There are two types of torque stops currently used. Refer to the illustrations below for adjustment of each
type.
1. After aligning clutches, adjust torque stop by
loosening lock nut and rotating stop to proper
clearance as shown. Hold torque stop and tighten
jam nut to 15-17 ft. lbs. (21-23.5 Nm).
ENGINE MOUNT TORQUE STOP
Adjust gap between stop and engine
mount to .010 - .030 (.25 - .75 mm)
.005 (.13 mm)
Engine Mount
Torque Stop
Lock
Nut
CLUTCHING
CRANKCASE TORQUE STOP
Adjust gap between stop and engine
crankcase to apply slight pre--load
for Race applications.
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