Driven Clutch Assembly; Driven Clutch Bushing Service - Polaris SPORTSMAN 400 2003 Service Manual

DRIVEN CLUTCH ASSEMBLY

Moveable
Example: Helix Sheave
2 - - 1
Spring/ 2 - - 2
Position 1 - - 1
2 - - 3
1 - - 2
1 - - 3
Refer to General Information Chapter 1 for driv-
en clutch spring color and production setting.
1. Install moveable sheave with spacer washers.
Important: At least one spacer washer must be
installed. Teflont bushings are self-lubricating.
Do not apply oil or grease to the bushings.
2. Install spring, inserting spring tab into proper hole
in moveable sheave.
3. Insert spring tab into proper hole in helix. See
specifications at the beginning of this section.
The driven clutch, helix/moveable assembly has
several different spring locations which affect clutch
shifting and RPMs. The greatest amount of spring
tension will raise engine RPMs during clutch upshift
and allow quicker backshift or downshift when pulling
or negotiating a hill, for example. The least amount of
tension will create a slower downshift and a harder
upshift.
Align boss spline
to install helix
4. Line up boss spline and push helix down until it
engages the splines 1/2² to 3/4².
Spring
Tension
5. While holding downward pressure on helix, wind
Heavy
moveable
approximately 1/3 turn (120°).
6. Push helix into place and install snap ring.
Soft
DRIVEN CLUTCH BUSHING
SERVICE
NOTE:Bushings are installed at the factory using
Loctitet. In order to remove the bushing it will be
necessary to apply heat. A press can be used to
remove and install some of the bushings. Be sure to
support the sheave or cover as close as possible to
the bushing bore when using a press.
1. Install Main Puller Adapter (#8) (PN 5020632)
onto the Piston Pin Puller (PN 2870386).
2. Insert Adapter Reducer (#9) (PN 5010279) onto
the puller, sliding it inside the main adapter.
1/3
turn
sheave
Main Puller Adapter (#8)
Adapter
Reducer (#9)
Piston Pin Puller
(PN 2870386)
CLUTCH
counterclockwise
6.21