Driven Clutch Assembly; Belt To Sheave Clearance Inspection; Belt To Sheave Clearance Adjustment - Polaris 2007 Two Stroke Service Manual

CLUTCHING
3. Compress the roller assembly to access the snap ring. Lock
the clutch compression tool chain to hold the roller
assembly down.
4. Carefully remove the snap ring.
5. Slowly release the compression tool.
WARNING
Wear eye protection when removing and installing the
roller assembly.
6. Disassemble the clutch components. Replace damaged or
worn components.

Driven Clutch Assembly

1. Clean the components with clutch cleaner. Reassemble the
clutch components. Reference the illustration for order of
assembly.
2. Visually align the wide notch on shaft with the wide
opening on the roller assembly. Place the roller assembly
on the spring.
3. While keeping the roller assembly centered on the shaft,
compress the roller assembly and spring down into the
moveable sheave enough to expose the snap ring groove.
4. Install the snap ring, then release the compression tool.
5. On dual-angled Team helixes, locate the desired angles
etched on the helix cover. Install the helix so that the desired
ramps fit around the two rollers. Push the helix down into
the sheave, while keeping the fastener holes aligned.
6. Torque the helix fasteners to specification.

Belt to Sheave Clearance Inspection

The distance between the belt and the moveable sheave on the
drive clutch is very important. This distance controls the starting
ratio (lowers starting ratio is most preferable) and the position
of the clutch weight to engine RPM.
The distance between the belt and movable sheave should be as
close to .020" (.5 mm) as possible with out creating drag on the
belt when positioned around the hub at the bottom of the
sheaves.
1. Force the belt (1) to the stationary sheave (toward engine)
of the drive clutch.
NOTE: Measure total belt to sheave clearance with a
new belt installed.
6.22
2. Install a feeler gage between the belt and moveable sheave
3. Distance should be .005" - .035" (.1 - .9 mm)
Belt to Sheave Clearance: .005" - .035" (.1 - .9 mm)

Belt to Sheave Clearance Adjustment

Belt to Sheave clearance can be adjusted in two ways:
1. Try several new belts to achieve proper clearance.
2. You can add or remove shims from under the spider to
increase or decrease the belt to sheave clearance. See
"Spider Indexing" on page 6.18.
NOTE: Belts with various widths will affect belt
deflection since they will fit differently in the driven
clutch. See "Belt
page 6.23.
2
1
= In. / mm.
Deflection Inspection" on