Snowmobile Polaris (2006 year). Instruction - part 37

 

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Snowmobile Polaris (2006 year). Instruction - part 37

 

 

7.3

CLUTCHING

SPECIAL CLUTCH TOOLS

CLUTCH TOOLS

All drive clutch maintenance, disassembly and assembly must 
be performed only by an authorized Polaris dealer who has 
attended current model Dealer Service Seminars, has received 
a certificate of completion, and displays the Polaris Servicing 
Dealer decal.

Because of the critical nature and precision balance 
incorporated into the drive clutch, it is absolutely essential that 
no attempt at clutch disassembly and/or repair be made 
without factory authorized tools and service procedures. Refer 
to the Service Tool Catalog (PN PU03-141) for photos and 
descriptions of all tools. A tool catalog update may be 
available through the SPX parts department (Phone Number 1-
800-328-6657). 

‹

 = Required Dealer Tool

Table 7-1: Clutch Tools

Offset Alignment Tool

PS-46998

‹1999 - Current 440, 550 Fuji Engine Drive Clutch Puller

2872084 

‹1999 - Current 600,700,800 Domestic Engine Clutch Puller

2871855 

‹1999 - 2001 700,800 XCR Triple Fuji Engine Clutch Puller

2872085 

Replacement Handle for ALL Clutch Pullers

5020326

‹Drive Clutch Holding Wrench

9314177-A

Strap Wrench

PU-45419

Replacement Strap

305085

Drive Clutch Spider Nut Socket

2870338

Drive Clutch Spider Removal and Spider Installation Tool

2870341-A

Pin Centering Tool

2870401

Clutch Pin Installation Tool

2870402

Clutch Pin Punch

2870507

‹Tapered Reamer for Drive Clutch Bore

2870576

‹Roller Pin Tool

2870910-A

‹Drive Clutch Button Removal Tool

2870985

‹Clutch Bushing Replacement Tool Kit

2871025

‹Primary Clutch Compression Tool

8700220

‹Clutch Holding Fixture

2871358

‹Clutch Compression Tool

8700220

‹Spider Assembly Tool

8700221

‹Clutch Compression Tool Extensions for TEAM driven

PS-45909

‹Clutch Pilot Tool

 (used with the 2871358 to compress the clutch)

PU-45779

Drive Clutch Compression Tool

 (compresses drive clutch whole still on the engine)

2871173

7.4

CLUTCHING

DRIVE BELT

BELT INSPECTION

1.

Measure the belt width and replace it if it is worn severely.
Generally a belt should be replaced if the clutches can no
longer be adjusted to provide the proper belt deflection.

• Top Edges have been trimmed on some drive belts. It 

will be necessary to project the side profiles and 
measure from corner to corner.

• Place a straight edge on each side of the drive belt and 

measure the distance where the straight edges intersect 
at the top (A,B).

2.

Inspect the belt for loose cords. missing cogs, cracks,
abrasions, thin spots or excessive wear spots. Replace if
necessary.

3.

Inspect the belt for hour glassing (extreme circular wear in
at least one spot an on both sides of the belt). Hour
glassing occurs when the drive train does not move and the
drive clutch engages the belt. Example would be taking off
while the track is frozen to the ground. Remember to
always warm up the track and free it from the ground.

BELT DIAGNOSIS

BELT

A

B

Table 7-2: BELT WEAR / BURN DIAGNOSIS

POSSIBLE CAUSE

SOLUTION

Driving at or about engagement RPM for extended periods of time in any type of 
snow condition.

Drive at higher RPM if possible. Gear the machine down. Make sure belt deflection is 
at 1 1/4” to achieve optimum starting ratio.

Cold weather startups

Be patient. Warm up engine at least 5 minutes or until it readily responds to throttle 
input. For the quickest most efficient drive away in extreme cold weather, take drive 
belt off machine and bring it in to a warm environment. Break skis and track loose 
from the snow. Engage throttle aggressively for short durations for initial cold drive 
away

Towing another machine at or about engagement RPM

When possible, do not go in deep snow when towing another machine. Use fast, 
effective throttle to engage the clutch. Not all machines are intended for pulling 
heavy loads or other machines.

Spinning track while vehicle is stuck (high RPM, low vehicle speed, high ambient 
temp. Example: 8000 RPM, 10mph actual vehicle speed and 60 m.p.h. indicated on 
speedometer.

Lower the gear ratio. Remove windage plates from driven clutch. If possible, move to 
better snow conditions and reduce RPM. Avoid riding in very high ambient 
temperatures

Ice and snow piled up between track and tunnel overnight or after stopping for a long 
period of time (enough to re-freeze the snow).

Break loose snow and ice under tunnel. Allow longer than normal warm-up. Allow 
belt to warm sufficiently and increase grip ability on clutch sheaves. Use fast, 
effective throttle when engaging clutch.

Poor running engine (Bog, Miss, Backfire, etc.)

Maintain good state of tune including throttle and choke synchronization. Check for 
fouled spark plug(s). Check for foreign material in carbs. Make sure no water or ice is 
present in the fuel tank, lines, or carburetors.

Loading machine on trailer

Use caution when loading machine. Carbide skags may gouge into trailer and prevent 
drive train from spinning freely. Use enough speed to drive completely onto trailer. If 
machine cannot be driven completely onto trailer, it may need to be pulled or pushed 
to avoid belt wear / burning.

Clutch malfunction

Check for correct clutch components, or damage on the clutch

Slow, easy belt engagement - easing on the throttle

Use fast, effective throttle to engage the clutch.

7.5

CLUTCHING

DRIVE BELT REMOVAL WITH TEAM 
CLUTCH

NOTE:  Before attempting to remove the drive belt, 
verify the engine is in forward mode, not reverse 
(PERC) or, the chaincase is in forward mode (PERC 
4). Turn the key to the “OFF” position and allow the 
engine to come to a complete stop.

To ensure belt life, install belts so they operate in the same 
direction of rotation. Position the identification numbers so 
that you can read them standing on left side of machine. This 
will keep the belt rotating in the same direction. If belt has 
been operated with numbers readable from right side of 
machine, re-install belt in this direction.

1.

Remove the clutch guard retaining pin, and open the clutch
guard.

2.

Apply and lock the parking brake.

3.

Insert the “L” wrench (A) into the threaded hole (B)
located on the driven clutch, and turn it clockwise until the
clutch sheaves are in the open position (C).

NOTE:  L wrench PN 2874857

4.

Remove the drive belt.

BELT INSTALLATION (Team Driven Clutch)

1.

With the “L” wrench inserted into the threaded into hole
(B) and the sheaves in the open position (C), install the
drive belt.

NOTE:  Install belt so that the numbers can be read 
correctly on the left side of the machine.

2.

Turn the “L” wrench counter clockwise until the driven
clutch sheaves are in the closed position. 

3.

Remove the “L” wrench.

4.

Close the clutch cover and secure the cover with the cover
pin.

A

B

C

D

E

WARNING

It is very important to remove the L wrench after the belt 

is installed or damage to the clutch will occur.

 

 

 

 

 

 

 

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