Polaris 2003 Pro X Service Manual page 180

CLUTCHING
9. Place the spider on the vise anvil and drive the
roller pin through to the second land of the spider.
NOTE: Care must be taken to ensure that the pin
is started straight. Aluminum burrs could pass
through into the roller bushing causing it to bind
and stick. Care must also be taken to ensure that
the roller remains aligned when the pin is driven
through. Roller bushing could be damaged
causing premature wear and roller failure.
10. Center the pin in the spider lands.
11. Install new buttons into the spider.
12. Assemble the moveable sheave and spider to the
stationary sheave but do not tighten yet.
13. Mark each leg of the spider and each tower with an
A, B, or C. With the moveable sheave open
(neutral position), insert the appropriate feeler
gauge between a button and a tower and leave it in
place (note the size of the feeler gauge used).
Measure and record the reading at the other 2 legs.
NOTE: Measurement must be taken at the bottom
of the tower (neutral position).
14. Install the required amount of shims to achieve
.000" (zero) clearance. NOTE: All shims are to
be installed on the drive side of the spider legs.
NOTE: Moveable must not bind in any position
when cycled up or down. Refer to Snowmobile
Repair Manual for general procedures.
15. Install weights with drive head of weight pin
leading and nut trailing. Torque nuts to 30 in. lbs.
16. Assemble the clutch completely.
spider to 200 ft. lbs (27.6 kg-m). Torque the jam
nut to 235 ft. lbs (32.4 kg-m). Torque the cover
plate bolts to 90 in. lbs. (1.04 kg-m).
17. If the clutch taper bore is rough or appears to have
spun on the crankshaft, the bore taper should be
trued using the tapered reamer (PN 2870576).
Place the reamer in a vise, lubricating with cutting
oil, and clean up the taper by manually rotating the
clutch clockwise.
18. Position the clutch on the engine crankshaft.
Install the retaining bushing and bolt. Using the
strap wrench (PN 2870336) to hold the clutch,
torque the retaining (7/16") bolt to 40-45 ft. lbs
(5.5-6.2 kg-m) or 14mm bolt to 50 ft. lbs. NOTE:
Never use an air impact wrench for installing or
removing a drive clutch. This could cause the
spider torque value to be reduced and/or engine
crankshaft damage.
4.48
Step 9.
Torque the
Step 13.
Step 14.