Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 156 / 289

CLUTCH
6.14
NOTE: Pinch the sheaves lightly together with clamp
to prevent the belt from being pushed into the driven
sheave.
1. Place a straight edge on top of the belt between
drive and driven clutch.
2. Push down on drive belt until it is lightly tensioned.
3. Measure belt deflection as shown in photo.
NOTE: If belt deflection is out of specification, adjust
by removing or adding shims between the driven
clutch sheaves.
G
Remove shims to decrease belt
deflection
G
Add shims to increase belt deflection
See DRIVEN CLUTCH
DISASSEMBLY/INSPECTION, Pages 6.19 - 6.20.
NOTE: At least one shim must remain between the
inner and outer sheave of the driven clutch. If proper
belt deflection cannot be obtained, measure drive belt
width, length, and center distance of drive and driven
clutch, outlined in this section; all have an effect on
belt deflection.
DRIVE BELT
REMOVAL/INSPECTION
1. Remove outer PVT cover as described in PVT
Disassembly.
2. Mark drive belt direction of rotation so that it can
be installed in the same direction. NOTE:
Normally positioned so part numbers are easily
read.
3. To remove drive belt: apply brake, pull upward
and rearward on belt to open driven clutch
sheaves, pull out and down on belt to slip over the
driven clutch outer sheave.
Projected Belt
Width
Belt Width:
New 1.174 - 1.188
″
(2.98-3.02 cm)
Wear Limit 1.125
″
(2.86 cm)
4. Measure belt width and replace if worn severely.
Generally, belt should be replaced if clutches can
no longer be adjusted to provide proper belt
deflection.
G
The top edges have been trimmed on
some drive belts. It will be necessary
to project the side profiles and
measure from corner to corner.
G
Place a straight edge on each side of
the drive belt.
G
Place another straight edge on top of
belt.
G
Measure the distance where the side
straight edges intersect the top, as
shown in the illustration below.