Drive Clutch Bushing Service; Clutch Offset - Polaris 2004-2005 Sportsman 6x6 Service Manual

1. Remove belt and install the Clutch Offset
Alignment Tool (PN 2870654) as shown.
2. With tool touching rear of driven clutch inner
sheave, the distance at point "A" should be 1/8".
If the distance is greater than 1/8" or less than 1/16",
clutch alignment must be adjusted as follows:
3. Remove drive and driven clutch.
Disassembly, Pages 6.5.
4. Remove PVT inner cover.
5. Loosen all engine mounts. Move front of engine
to the right or left slightly until alignment is correct.
6. Tighten engine mounts and verify alignment is
correct.
Center line
Measure offset above and below
centerline
7. Measure belt deflection and measure offset both
above and below sheave centerlines. Adjust if
necessary.
NOTE: On some models, minor adjustments can be
made by adding shims between the frame and front
lower left engine mount to increase the distance at
point "A". If a shim is present, it can be removed to
decrease the distance at point "A".
Shim Kit (PN 2200126)
6.16

CLUTCH OFFSET

See PVT
Important:
distance before adjusting offset.
1. Install offset alignment tool as shown.
Offset is correct when rear of tool contacts rear of
inner sheave with driven clutch pushed completely
inward on shaft and bolt torqued. Adjust offset by
adding or removing spacer washers between back of
driven clutch and spacer as shown.
Spacer Washer (PN 7556401)
DRIVE CLUTCH BUSHING
SERVICE
*Clutch Bushing Replacement Tool Kit (PN
2871226)
Stamp Qty. Part Description
#2
Offset Alignment Tool
(PN 2870654)
B
A
1/8I +0 / -- 1/16
3.2mm +0 / -- 1.6 mm)
Inspect clutch alignment and center
1 P--90 Drive/Driven
Clutch Bushing
Install Tool
CLUTCH
Part #
5020628