Drive Clutch Disassembly - Polaris IQ 2007 Service Manual

PVT System

Drive Clutch Disassembly

SPIDER BUTTON
COVER
COVER BEARING
RETAINER
CAUTION
Wear eye protection when servicing the drive clutch.
Sheaves must be marked to provide a reference point
for dutch balance and spider indexing. If the sheaves
are not marked and the spider washers are changed or
misplaced, the clutch may be out of balance and dam-
age to the clutch may result.
WARNING
Clutch spring is under extreme tension, use caution
when disassembling the clutch.
1. In a straight line, mark the sheaves and the cover with a
black marker or etched with a scribe.
2. Remove the clutch.
3. Place the drive clutch in the clutch compression tool (PN
8700220).
4. Compress the clutch in the compression tool, then secure
the chain.
5. Evenly remove the cover fasteners. The cover bushing may
be damaged if the cover is side-loaded or mis-aligned.
6. Carefully remove the tension from the compression tool.
7. Remove the cover and inspect the cover bushing. Replace
if damaged or worn.
NOTE: Replace the cover bushing if the inside
diameter is over 1.40" (28.95mm)
8. Remove the spring.
9. Mount the drive clutch securely in a drive clutch holding
7.14
ROLLER
WASHER ROLLER PIN
WASHER
SPRING
JAM NUT
SPIDER
SPACERS
CLUTCH SPACER
WEIGHT
WEIGHT PIN
BEARING SLEEVE
MOVEABLE SHEAVE
fixture (PN 2871358).
10. Remove the jam nut in a counterclockwise direction
(standard thread) using the drive clutch spider nut socket
(PN 2871358).
11. Install the spider removal tool (PN 2870341), and remove
the spider in a counterclockwise direction (standard
thread).
12. Measure the total thickness of the spacer washers that are
installed on top of the clutch spacer. Record the thickness
of these spacer washers.
13. Inspect both sheave surfaces for wear or damage.
14. Inspect the moveable sheave bushing for wear or damage.
15. Remove all three drive clutch weights.
16. Inspect each weight. The surface should be smooth, with no
waves or galling. Place bolt inside weight to check
flyweight bushing and pin surface for wear by rocking the
weight back and forth.
17. Inspect all the rollers, bushings and roller pins by pulling a
flat metal rod across the roller.
18. Roller can also be inspected by rolling with a finger to feel
for flat spots, roughness, or loose bushing.
NOTE: The flyweight bushing is not replaceable. If
flyweight bushing is damaged both the flyweight, pin
and nut will need to be replaced.
19. Inspect to see if the roller and bushing are separating.
20. Bushing must fit tightly in roller.
21. Replace roller and pin if roller fails to roll smoothly (no flat
spots) or if the bushing is loose or worn.
MOVEABLE INSERT
STATIONARY SHEAVE