Drive Clutch Disassembly; Clutch Assembly - Polaris 340 CLASSIC 2006 Manual

DRIVE CLUTCH DISASSEMBLY

Table 7-3: Drive Clutch Service Components
ITEM DESCRIPTION
1 Index mark
2 Cover bolts and washers
3 Clutch cover
4 Cover bushing
5 Clutch spring
6 Spider nut
7 Spider
8 Moveable sheave
9 Moveable sheave bushing
10 Stationary sheave
11 Clutch weight pin nut
12 Clutch weight pin
13 Clutch weight
14 Pin
15 Roller
16 Shim
17 Stepped washer
18 Washer stack
CAUTION
Eye protection must be worn during disassembly.
CAUTION
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 will 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 (1).
2. Remove the clutch. See "DRIVE CLUTCH REMOVAL"
on page 7.10
3. Place the drive clutch in the clutch compression tool (PN
TORQUE SPECIFICATION/
NOTES
90in-lb (10Nm)
This should facing the trailing
side of the clutch
This should be facing the
leading side of the clutch
Make sure that the stepped
washer is on top of the washer
stack and that the washer has
the step facing the sheave side.
8700220).
4. Compress the clutch in the compression tool and lock the
compression tool, making sure that all cover bolts (2) are
accessible.
5. Remove the cover bolts and washers (2) evenly and
carefully. Do not allow side loading or misalignment of the
cover (3), or the bushing (4) can be damaged.
6. Carefully remove the tension from the compression tool.
7. Remove the cover (3) and inspect the cover bushing (E)
and replace it if it is damaged or worn.
8. Remove the spring (5).
NOTE: Replace the cover bushing if the inside
diameter is over 1.40" (28.95mm)
9. Mount the drive clutch securely in a drive clutch holding
fixture (PN 2871358).
10. Remove the jam nut (6) 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 (7) in a counterclockwise direction (standard
thread).
12. Measure the total thickness of the spacer washers (18) that
are installed under the stepped washer (17) and record the
thickness of these spacer washers. Make sure that you note
that the stepped washer is on the top of the spacer stack.
13. Inspect both sheave surfaces (8,10) for wear or damage.
14. Inspect the moveable sheave bushing (9) for wear or
damage.
15. Remove all three drive clutch weights (13).
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 (15), bushings (16) and roller pins
(14) 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. Also 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.
22. Assembly is the reverse order of disassembly. Note the
specifications and notes in See "Drive Clutch Service
Components" on page 7.13

CLUTCH ASSEMBLY

1. Assemble the rollers, bushings and roller pins if they were
CLUTCHING
7.13