Polaris Sportsman 400, Service Manual

Page: 213 / 381

CLUTCH
6.29
DRIVEN CLUTCH ASSEMBLY
1. Install moveable sheave with spacer washers.
Important: At least one spacer washer must be
installed. Teflon bushings are self-lubricating. Do
not apply oil or grease to the bushings.
2. Install spring, inserting spring tab into proper hole in
moveable sheave.
3. Insert spring tab into proper hole in helix. See
specifications at the beginning of this section.
The driven clutch, helix/moveable assembly has several
different spring locations which affect clutch shifting and
RPMs. The greatest amount of spring tension will raise
engine RPMs during clutch upshift and allow quicker
backshift or downshift when pulling or negotiating a hill,
for example. The least amount of tension will create a
slower downshift and a harder upshift.
4. Line up boss spline and push helix down until it
engages the splines 1/2
″
to 3/4
″
.
5. While holding downward pressure on helix, wind
moveable sheave counterclockwise approximately
1/3 turn (120
°
).
6. Push helix into place and install snap ring.
Moveable Spring
Example: Helix Sheave Tension
2 -- 1 Heavy
Spring/ 2 -- 2
Position 1 -- 1
2 -- 3
1 -- 2
1 -- 3 Soft
Refer to General Information Chapter 1 for driv-
en clutch spring color and production setting.
Align boss spline
to install helix
1/3
turn