Polaris 2005 SPORTSMAN 500 Servise Manual page 164

CLUTCHING
Moveable Sheave Bushing Inspection
2. Inspect the Teflont coating on the moveable
sheave bushing.
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass
than Teflont is visible on the bushing.
Refer to bushing replacement in this
chapter.
Roller, Pin and Thrust Washer Inspection
3. Inspect all rollers, bushings and roller pins by
pulling a flat metal rod across the roller. Turn roller
with your finger. If you notice resistance, galling,
or flat spots, replace rollers, pins and thrust
washers in sets of three. Also inspect to see if
roller and bushing are separating. Bushing must
fit tightly in roller. Use the Roller Pin Tool (PN
2870910) to replace rollers and pins. Take care
not to damage roller bushing or bearing surface of
the new pin during installation.
4. Rubber backed buttons can and should be used in
all ATV clutches if the hollow roller pin is changed
to a solid roller pin. NOTE: The rubber side of the
6.12
button is positioned toward the solid roller pin. It is
recommended to switch all buttons to the rubber
version during service (if needed).
NON- -EBS - - DRIVE CLUTCH
REASSEMBLY
NOTE: On Non--EBS clutches it is important that the
same number and thickness of washers are
reinstalled beneath the spider during assembly. The
Teflon bushings are self-lubricating. Do not apply oil
or grease to the bushings.
1. Reassemble drive clutch in the following
sequence. Be sure the "X", or the marks that were
made earlier, are aligned during each phase of
assembly.
a) "X", or the marks that were made earlier on
cover
b) X on spider, making sure spacer washers
are installed
positioned properly in recess.
c) "X", or the marks that were made earlier
under weight
underneath spider and