Polaris 2005 SPORTSMAN 500 Servise Manual page 166

CLUTCHING
NON- -EBS - - DRIVE BELT
TENSION
NOTE: Belt tension is not adjustable on EBS
models.
NOTE: Pinch the sheaves lightly together with clamp
to prevent the belt from being pushed into the driven
sheave.
1. Place a straight edge on top of the belt between
drive and driven clutch.
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in illustration.
1 1/8" (28.5 mm)
Belt Deflection (Tension):
1 1/8" (2.9 cm) - 1 1/4" (3.2 cm)
If belt deflection is out of specification, adjust by
removing or adding shims between the driven clutch
sheaves.
Remove shims to decrease belt
S
deflection
Add shims to increase belt deflection
S
See Driven Clutch Disassembly/Inspection, Pages
6.19 - 6.20.
NOTE: At least one shim must remain between the
inner and outer sheave of the driven clutch. If proper
belt deflection cannot be obtained, measure drive belt
width, length, and center distance of drive and driven
clutch, outlined in this section; all have an effect on
belt deflection.
6.14
Straight Edge
ALL MODELS - - DRIVE BELT
REMOVAL/INSPECTION
1. Remove outer PVT cover as described in PVT
Disassembly.
2. Mark drive belt direction of rotation so that it can
be installed in the same direction.
Normally positioned so part numbers are easily
read.
3. To remove drive belt, apply brake, pull upward
and rearward on belt to open driven clutch
sheaves, pull out and down on belt to slip over the
driven clutch outer sheave.
NOTE: When reinstalling the belt with the drive clutch
and driven clutch already removed follow these steps:
Install the driven clutch.
S
Install the belt onto the driven clutch.
S
Loop the drive clutch through the
S
belt.
Install the drive clutch onto the
S
crankshaft.
NOTE: