Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 153 / 289

CLUTCH
6.11
DRIVE CLUTCH
DISASSEMBLY
Mark
“X”
Mark
1. Using a permanent marker, mark the cover,
spider, moveable and stationary sheaves, and
steel post to the stationary sheave for reference.
The X’s may not have been in alignment before
disassembly.
2. Remove cover bolts evenly in a cross pattern, and
remove cover plate.
A
Cover Bushing Inspection:
Replace the cover bushing if more
brass than Teflon
t
is visible on
the bushing. Refer to bushing re-
placement in this chapter.
3. Inspect cover bushing (A). The outer cover
bushing is manufactured with a Teflon
t
coating.
Bushing wear is determined by the amount of
Teflon
t
remaining on the bushing.
Inspect shaft
4. Inspect area on shaft where bushing rides for
wear, galling, nicks, or scratches. Replace clutch
assembly if worn or damaged.
5. Remove and inspect spring. (See Page 6.8)
SPIDER REMOVAL
Clutch Holding Fixture:
(PN 2871358)
Spider Removal Tool:
(PN 2870341)
1. Install clutch in holding fixture and loosen the
spider (counterclockwise) using spider removal
tool.
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. Be sure to note the number
and thickness of these washers.