Clutch Assembly; Spider Indexing - Polaris 2007 Two Stroke Service Manual

CLUTCHING

Clutch Assembly

1. Assemble the rollers, bushings and roller pins if they were
removed.
2. Install the head of the weight pin so that it is on the leading
side of rotation. This will orientate the nut on the trailing
side of rotation.
3. Torque weight pin to 30 in-lb. (3Nm).
4. Place the moveable sheave onto the stationary sheave.
5. Place the same number of spacers on top of the stepped
spacer onto the shaft of the stationary sheave.
CLUTCH SPACER
JAM NUT
6. Thread the spider onto the stationary sheave shaft.
7. Index the spider. See "Spider Indexing" on page 6.18.
8. Using the spider tool (PN 2870341) torque to 200 ft.-lb.
(276Nm).
9. Install the jam nut (6) onto the shaft and torque it to 235 ft.-
lb. (324 Nm).
10. Place the drive spring on the shaft.
11. Place the cover onto the clutch and torque the cover
fasteners to 90 in-lb. (10Nm).
NOTE: Do not allow side loading or mis-alignment
of the cover or the bushing may become damaged.
6.18
SPACERS

Spider Indexing

NOTE: Spider indexing effects belt to sheave
clearance and clutch balance. Please read all
procedures before proceeding.
1. Remove and disassemble clutch
2. Add or remove spider washers as required to achieve
desired belt to sheave clearance. Make sure that the stepped
washer (A) is on the bottom of the spacer stack (B). For
example: If belt to sheave clearance is .020" too large,
removing one .020" shim will position the movable sheave
closer to the fixed sheave reducing belt to sheave clearance
by .020".
3. Place the correct number of spacer washers (B) beneath the
spider. The following washers are available for fine tuning:
• 5210752 - .020" (.51mm)
• 5242981 - .025" (.63mm)
• 5210753 - .032" (.81mm)
• 5210754 - .050" (1.27mm)
• Clutch Spacer - .130" (3.3mm)
4. Install spider washer(s) and spider aligning the "X" with the
moveable sheave's "X". Notice as the spider seat location
is changed, the sheave marks made before disassembly no
longer align (C). There are two ways to bring the sheave
marks into alignment.
(A)
(B)