Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 157 / 289

CLUTCH
6.15
5. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear.
Replace if necessary.
6. Inspect belt for hour glassing (extreme circular
wear in at least one spot and on both sides of the
belt). Hour glassing occurs when the drive train
does not move and the drive clutch engages the
belt.
Center
Distance
Clutch Center Distance -
10
″
+.1 / -.05 (254 +2.5 / -1.3mm)
Belt Nominal Length - 40.875
″±
3/16
( 103.8 cm
±
.48 cm)
7. Measure belt length with a tape measure around
the outer circumference of the belt. Belts which
measure longer than nominal length may require
driven shimming or engine adjustment for a
longer center distance to obtain proper belt
deflection. Belts which measure shorter than
nominal length may require driven shimming or a
shorter center distance. Remember, proper belt
deflection is the desired goal -- not a specific
center distance.
8. Replace belt if worn past the service limit. Belts
with thin spots, burn marks, etc., should be
replaced to eliminate noise, vibration, or erratic
PVT operation. See Troubleshooting Chart at the
end of this chapter for possible causes. NOTE: If
a new belt is installed, check belt deflection.
DRIVE BELT INSTALLATION
1. Loop belt over drive and over top of driven
sheave.
2. While pushing down on top of belt, turn the back
or moveable driven sheave clockwise.
3. The belt then should be able to be pushed down
into and between the sheaves.
NOTE: Be sure to position belt so part number is
easily read.
CLUTCH ALIGNMENT
Offset Alignment Tool
should contact rear edge
of driven clutch sheave
Driven Clutch Offset
To adjust, add or remove
washers from behind the
driven clutch