Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 154 / 289

CLUTCH
6.12
Moveable Sheave Bushing Inspection
2. Inspect the Teflon
t
coating on the moveable
sheave bushing.
Teflon
t
Moveable Sheave Bushing Inspection:
Replace the cover bushing if more
brass than Teflon
t
is visible on the
bushing. Refer to bushing replace-
ment in this chapter.
ROLLER, PIN AND THRUST
WASHER INSPECTION
1. Inspect all rollers, bushings and roller pins by
pulling a flat metal rod across the roller. Turn roller
with your finger. If you notice resistance, galling,
or flat spots, replace rollers, pins and thrust
washers in sets of three. Also inspect to see if
roller and bushing are separating. Bushing must
fit tightly in roller. Use the Roller Pin Tool ( PN
2870910 ) to replace rollers and pins. Take care
not to damage roller bushing or bearing surface of
the new pin during installation.
2. Rubber backed buttons can be used in all ATV
clutches if the hollow roller pin is changed to the
solid roller pin. NOTE: The rubber side of the
button is positioned toward the solid roller pin.
DRIVE CLUTCH ASSEMBLY
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon
t
bushings are
self-lubricating. Do not apply oil or grease to the
bushings .
1. Reassemble drive clutch in the following
sequence. Be sure the “X”, or the marks that were
made earlier, are aligned during each phase of
assembly)
a)“X”, or the marks that were made earlier, on
cover
b) spider, making sure spacer washers are
installed underneath spider and
positioned properly in recess