Snowmobile Polaris Two Stroke (2007 year). Instruction - part 41

6.15

CLUTCHING

6

DRIVE CLUTCH

Identification

Every clutch will have the last three digits of the clutch part number etched on to the cover (A). The “X” (B) marking is an index
mark where the clutch cover (C), clutch spider (D) and the stationary sheave (E) should line up when the clutch is assembled.

Drive Clutch Removal 

NOTE:  All clutch tools can be found at the beginning of this chapter. 

1.

Remove the belt.

2.

Place the clutch holding tool (PN 9314177-A) on the drive clutch.

3.

Remove the drive clutch retaining bolt. Note the placement and number of washers on retaining bolt.

4.

Insert the correct clutch puller into the retaining bolt hole.

5.

Tighten the puller into the clutch. If the clutch does not come off, strike the clutch puller head with a hammer. If the clutch
does not “pop” off, continue to tighten the clutch puller, and repeat this step.

CAUTION

Do not use an impact wrench to remove or install the 
clutch bolt or clutch puller. Damage to the clutch and/or 
crankshaft can occur.

A

B

C

D

B

E

(Domestic style)

6.16

CLUTCHING

Drive Clutch Disassembly

1.

In a straight line, mark the sheaves and the cover with a
black marker or etched with a scribe.

2.

Remove the clutch. 

3.

Place the drive clutch in the clutch compression tool (PN
8700220).

4.

Compress the clutch in the compression tool, then secure
the chain.

5.

Evenly remove the cover fasteners. The cover bushing may
be damaged if the cover is side-loaded or mis-aligned.

6.

Carefully remove the tension from the compression tool.

7.

Remove the cover and inspect the cover bushing. Replace
if damaged or worn.

NOTE: Replace the cover bushing if the inside
diameter is over 1.40

″ (28.95mm)

8.

Remove the spring.

9.

Mount the drive clutch securely in a drive clutch holding
fixture (PN 2871358).

10. Remove the jam nut in a counterclockwise direction

(standard thread) using the drive clutch spider nut socket
(PN 2871358).

11. Install the spider removal tool (PN 2870341), and remove

the spider in a counterclockwise direction (standard
thread).

12. Measure the total thickness of the spacer washers that are

installed on top of the clutch spacer. Record the thickness
of these spacer washers.

13. Inspect both sheave surfaces for wear or damage.

14. Inspect the moveable sheave bushing for wear or damage.

15. Remove all three drive clutch weights.

16. Inspect each weight. The surface should be smooth, with

no waves or galling. Place bolt inside weight to check
flyweight bushing and pin surface for wear by rocking the
weight back and forth.

17. Inspect all the rollers, bushings and roller pins by pulling a

flat metal rod across the roller.

18. Roller can also be inspected by rolling with a finger to feel

for flat spots, roughness, or loose bushing.

NOTE: The flyweight bushing is not replaceable. If
flyweight bushing is damaged both the flyweight, pin
and nut will need to be replaced. 

19. Inspect to see if the roller and bushing are separating.

20. Bushing must fit tightly in roller.

21. Replace roller and pin if roller fails to roll smoothly (no flat

spots) or if the bushing is loose or worn.

STATIONARY SHEAVE

MOVEABLE SHEAVE

SPIDER

COVER

SPRING

JAM NUT

SPACERS

CLUTCH SPACER

BEARING SLEEVE

MOVEABLE INSERT

COVER BEARING

RETAINER

SPIDER BUTTON

WASHER

ROLLER

ROLLER PIN

WASHER

WEIGHT

WEIGHT PIN

CAUTION

Wear eye protection when servicing the drive clutch.
Sheaves must be marked to provide a reference point 
for dutch balance and spider indexing. If the sheaves 
are not marked and the spider washers are changed or 
misplaced, the clutch may be out of balance and dam-
age to the clutch may result. 

WARNING

Clutch spring is under extreme tension, use caution 
when disassembling the clutch.

6.17

CLUTCHING

6

Roller Removal

1.

With the spider in a vise start removing the spider buttons
by drilling a 0.18" hole in the center of a button on one side
of the spider.

2.

Place spider on a vise or in an arbor press.

3.

Place a pin punch through the spider button hole and drive
the opposite button and pin out.

4.

Remove shims (if any are installed) and note their location.

5.

Flip the spider over and tap out the holed button.

Roller Installation

NOTE:  CAUTION: Use care to start the pin straight.
Aluminum burrs could pass through into the roller
bushing causing it to bind and stick. Also use care
to make sure the roller remains aligned when the pin
is driven through. The roller busing could be
damaged causing premature wear and roller failure.

1.

Drive pin into the spider leg.100" -.125" (0.25 - 0.32cm)
beyond the first land of the spider leg.

2.

Install one washer on the portion of the pin that is
protruding from the spider leg.

3.

Install new buttons into the spider

4.

Place roller in spider leg and center it on the pin.

5.

Place a second washer on the other side of the roller.

6.

Place the spider on a vise.

7.

Install pin centering tool (PN 2870401).

8.

Drive the roller pin through the second land of the spider.

9.

Repeat process for the other two rollers.

10. Measure the width of the spider leg with the buttons

installed (9) and record the measurement. Specification is

1.496" (37.99mm).

11. Measure the width of the moveable sheave towers.

Specification is 1.50" (38.1mm).

12. Subtract the spider measurement form the tower

measurement. The clearance between the spider buttons
and the moveable sheave towers is .002" - .004" (.05 -
.10mm).

SPIDER

BUTTON

SHIM

WASHER

ROLLER

ROLLER PIN

WASHER

6.18

CLUTCHING

Clutch Assembly

1.

Assemble the rollers, bushings and roller pins if they were
removed.

2.

Install the head of the weight pin so that it is on the leading
side of rotation. This will orientate the nut on the trailing
side of rotation.

3.

Torque weight pin to 30 in-lb. (3Nm).

4.

Place the moveable sheave onto the stationary sheave.

5.

Place the same number of spacers on top of the stepped
spacer onto the shaft of the stationary sheave.

6.

Thread the spider onto the stationary sheave shaft.

7.

Index the spider. See “Spider Indexing” on page 6.18.

8.

Using the spider tool (PN 2870341) torque to 200 ft.-lb.
(276Nm).

9.

Install the jam nut (6) onto the shaft and torque it to 235 ft.-
lb. (324 Nm).

10. Place the drive spring on the shaft.

11. Place the cover onto the clutch and torque the cover

fasteners to 90 in-lb. (10Nm).

NOTE: Do not allow side loading or mis-alignment
of the cover or the bushing may become damaged.

Spider Indexing

NOTE: 

Spider indexing effects belt to sheave

clearance and clutch balance. Please read all
procedures before proceeding.

1.

Remove and disassemble clutch 

2.

Add or remove spider washers as required to achieve
desired belt to sheave clearance. Make sure that the stepped
washer (A) is on the bottom of the spacer stack (B). For
example: If belt to sheave clearance is .020

″ too large,

removing one .020

″ shim will position the movable sheave

closer to the fixed sheave reducing belt to sheave clearance
by .020

″.

3.

Place the correct number of spacer washers (B) beneath the
spider. The following washers are available for fine tuning:

• 5210752 - .020

″ (.51mm)

• 5242981 - .025

″ (.63mm)

• 5210753 - .032

″ (.81mm)

• 5210754 - .050

″ (1.27mm)

• Clutch Spacer - .130

″ (3.3mm)

4.

Install spider washer(s) and spider aligning the “X” with the
moveable sheave’s “X”. Notice as the spider seat location
is changed, the sheave marks made before disassembly no
longer align (C). There are two ways to bring the sheave
marks into alignment.

JAM NUT

SPACERS

CLUTCH SPACER

(A)

(B)