Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 162 / 289

CLUTCH
6.20
1. Apply and hold downward pressure on the helix,
or place driven clutch in the Clutch Compression
Tool ( PN 8700220 ).
2. Remove snap ring retainer.
Note hole location of spring
in helix and sheave
3. Note the location of the spring and remove helix.
4. Note the location of the spring in the moveable
sheave, and remove the spring.
5. Check alignment of tabs on spring. Replace the
spring if tabs are misaligned or the spring coils are
distorted.
6. Inspect ramp buttons in the moveable sheave and
replace if worn. NOTE: The ramp buttons are
secured by Torx
t
screws (T20).
Belt deflection adjustment
washers
7. Remove moveable sheave and note the number
of spacer washers. One spacer must remain
between the sheaves when adjusting belt
deflection.
Inspect bushings for wear
Moveable Sheave Bushing Inspection:
Replace the bushing if more brass than
Teflon
t
is visible on the bushing. Re-
fer to bushing replacement in this
chapter.
8. Inspect the Teflon
t
coating on the moveable
sheave bushing.
9. Inspect driven clutch faces for wear or damage.
10. Clean and inspect splines on helix and
transmission input shaft.
11. Lube splines with a light film of grease. Do not
lubricate the bushings!