Drive Clutch Inspection; Drive Clutch Disassembly - Polaris SPORTSMAN 400 2003 Service Manual

CLUTCH
SHIFT WEIGHT INSPECTION
1. Inspect as shown, using a clutch holding tool to
compress the moveable sheave. The contact
surface of the weight should be smooth and free
of dents or gall marks. Remove shift weight bolts
and weights.
Broken Worn
Inspect the weight pivot bore and pivot bolts for
wear or galling. If weights or bolts are worn or
broken, replace in sets of three with new bolts.
NOTE: A damaged shift weight is usually caused
by a damaged or stuck roller in the spider
assembly. See roller inspection, Page 6.12.
WARNING
The clutch assembly is a precisely balanced unit.
Never replace parts with used parts from another
clutch assembly!
All PVT maintenance or repairs should be performed
only by a certified Polaris Master Service Dealer
(MSD) technician who has received the proper
training and understands the procedures outlined in
this manual. Because of the critical nature and
precision balance incorporated into the PVT
system, it is absolutely essential that no attempt
at disassembly or repair be made without factory
authorized special tools and service procedures.
6.10
BUTTON TO TOWER
CLEARANCE INSPECTION
1. Inspect for any clearance between spider button
2. Inspect sheave surfaces.
Good
DRIVE CLUTCH
DISASSEMBLY
1. Using a permanent marker, mark the cover,
to tower. If clearance exists, replace all buttons
and inspect surface of towers.
Removal Page 6.12.
Button to Tower Clearance:
.000 - .001I
clutch as an assembly if worn, damaged or
cracked.
spider, and moveable and stationary sheaves for
reference, as the previous X's may not have been
in alignment before disassembly.
See Spider
Replace the entire
Mark
"X"
Mark