Drive Clutch Reassembly - Polaris SPORTSMAN 400 2003 Service Manual

CLUTCH
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).

DRIVE CLUTCH REASSEMBLY

NOTE: 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