Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 235 / 432

6.23
CLUTCHING
6
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
3. 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.
4. Rubber-backed buttons can and should be used in all
ATV clutches if the hollow roller pin is changed to a
solid roller pin.
NOTE: Rubber side of the button is positioned
toward the solid roller pin. It is recommended to
switch all buttons to the rubber version during
service (if needed).
Button To Tower Clearance Inspection
1. Inspect for any clearance between spider button to
tower. If clearance exists, replace all buttons and
inspect surface of towers. See “Spider Removal”
procedure.
2. Inspect sheave surfaces. Replace the entire clutch as
an assembly if worn, damaged or cracked.
Shift Weight Inspection
1. If clutch is not disassembled, inspect as shown, using
a clutch holding tool to compress the moveable
sheave. The contact surface of the weight should be
smooth and free of dents or gall marks. Remove shift
weight bolts and weights.
Button to Tower Clearance: .000-.001