6.20
CLUTCHING
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Clutch Assembly
NOTE: It is important that the same number and
thickness of washers are reinstalled beneath the
spider during assembly. The Teflon bushings are
self-lubricating.
Reassemble the drive clutch in the following sequence.
Be sure the “X”, or the marks that were made earlier are
aligned during each phase of assembly.
1. Install moveable sheave onto fixed sheave.
2. Install spider spacers. Use same quantity and
thickness as were removed.
3. Compress spider buttons for each tower and install
spider, making sure that “X”, or the marks that were
made earlier, on spider aligns with “X”, or the marks
that were made earlier, in moveable sheave.
4. Torque spider to specification using the holding fixture
and spider tool. Torque with smooth motion to avoid
damage to the stationary sheave.
5. Install shift weights using new lock nuts on the bolts.
6. Reinstall clutch spring.
7. Reinstall cover, aligning “X” mark with other marks.
8. Torque cover bolts evenly to specification.
Do not apply oil or grease to the bushings.
Spider Torque:
200 ft. lbs. (271 Nm)
Be sure the spider spacer washers are fully
seated in the recessed area in the spider.
Any misalignment will alter clutch balance.
Inverting the clutch while initially tightening the
spider will help position the washers.
Cover Screw Torque:
90 in. lbs. (10.4 Nm)
Rotation
Nut on trailing side
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