Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 152 / 289

CLUTCH
6.10
SHIFT WEIGHT INSPECTION
1. Remove shift weight bolts and weights. Inspect
as shown. The contact surface of the weight
should be smooth and free of dents or gall marks.
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, PIN AND THRUST
WASHER INSPECTION”, Page 6.12.
Broken Worn Good
BUTTON TO TOWER
CLEARANCE INSPECTION
1. Inspect for any clearance between spider button
to tower. If clearance exists, replace all buttons
and inspect surface of towers. See “SPIDER
REMOVAL” Page 6.11.
Button to Tower Clearance:
.000 - .001
I
2. Inspect sheave surfaces. Replace the entire
service clutch if worn, damaged or cracked.
WARNING
The clutch assembly is a precisely balanced unit.
Never replace parts with used parts from another
clutch assembly!
All PVT system maintenance repairs must be
performed only by an authorized Polaris service
technician who has attended a Polaris sponsored
service training seminar and understands the proper
procedures as 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.