Snowmobile Polaris PRO X (2003 year). Instruction - part 38

CLUTCHING

4.20

Spider Indexing

NOTE: Spider indexing affects clutch balance and belt
to sheave clearance. Read procedures carefully before
proceeding.

Before disassembling drive clutch, mark spider,
cover, moveable sheave, and stationary sheave in
line with a permanent marker as shown.

Disassemble drive clutch as described on page
4.20-4.21.

Take care to note the amount and

thickness of the shim washers under the spider.

Add or remove spider washers as required to
achieve desired belt to sheave clearance.

For example: If belt to sheave clearance is .020

too large, removing one .020

s shim will position

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

NOTE: The following washers are available for fine tuning:

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

Vary the amount and thickness of spacer washers
(Washer thickness may vary slightly).

Re-index marked spider leg to another tower.
This can be done because spider has little effect
on overall clutch balance.

Re-indexing the spider 1/3 turn clockwise, or 1 leg, will
allow the realignment of the moveable and stationary
sheaves as previously marked. For example:

.020

s or .032s washer removed - re-index

spider clockwise 1/3 turn

.050

s or .064s washer removed - re-index

spider clockwise 1/3 turn

Two .050

s or .064s washers removed -

re-index clockwise 2/3 turn

NOTE: Alignment marks should be within 1

s (25 mm) af-

ter final assembly and torquing.

PN 5132542

PN 5210754

.050

PN 5210753

.030

PN 5210752

.020

PN 5132542

Stepped washer in addi-

tion to one of the above shims for pre-
cise shimming

Washers:

CLUTCHING

4.21

Removal

Hold clutch with strap wrench. Remove drive clutch
retaining bolt, grease puller thread and tip lightly and
install puller into clutch.

Tighten puller with a

wrench, or strike t-bar with a hammer until clutch is
removed.

Slight galling or scoring of bore taper can usually be
corrected using a tapered reamer. Place reamer in
a vise and lubricate with cutting oil. Clean clutch
taper by manually rotating clutch clockwise. Do not
ream taper more than required to remove galling or
scoring. Never use power tools to ream taper of
drive clutch.

CAUTION:

Never use an air impact wrench for installing or removing
a drive clutch. It will loosen the spider torque value and
could cause engine crankshaft damage.

Identification

This number indicates internal clutch component varia-
tion for individual engines. For easy identification, refer
to the three numbers behind date code on clutch cover
plate. These numbers are the last three digits of the
clutch part number.

Strap Wrench PN 2870336

Clutch Puller PN 2872085 - 3/4-16x14mm
Clutch Puller XCF: 2872084

Tapered Reamer PN 2870576

Date Code

Last 3 digits of
part number

CLUTCHING

4.22

Disassembly and Inspection

Install drive clutch in clutch compression tool
(8700220). Mark both moveable and fixed sheave,
cover, and spider with a permanent marker.

CAUTION:

Sheaves must be marked to provide a reference point for
clutch balance and spider indexing. If the sheaves are
not marked, and spider shim washers are changed or
misplaced, the clutch will be out of balance and must be
replaced. See page 4.28 for indexing procedure.

Carefully and evenly remove cover attaching bolts.
Do not allow side loading or misalignment of cover or
bushing may be damaged. Remember there is
spring tension on the cover. Inspect cover bushing
for wear. See page NO TAG for inspection and repair
procedure.

Mount drive clutch securely in the holding fixture. On
models equipped with a spider jam nut (P-85
Clutches), remove jam nut in a counterclockwise
direction (standard thread) using the special tool.

Install spider removal tool and remove spider in a
counterclockwise direction (standard thread).

Drive Clutch Holding Fixture
PN 2871358

Drive Clutch Compression Tool
PN 8700220

Spider Spanner (Jam Nut) Tool

PN 2870338

Spider Removal Tool

PN 2872987

CLUTCHING

4.23

Disassembly, Cont.

Measure the total thickness of the spacer washers
installed beneath spider and record.

CAUTION:

NOTE: In order to maintain proper belt-to-sheave clear-
ance and clutch balance, the same washers (or equiva-
lent total thickness) must be reinstalled during assembly.
If sheaves are not marked, or if total thickness of existing
shim washers under spider is not recorded, clutch will be
out of balance when reassembled and must be replaced.
Be sure to follow indexing procedure on page 4.28 if belt-
to-sheave clearance is being adjusted.

Inspect both sheave surfaces for wear or damage.
Inspect movable sheave bushing. See page 4.43 for
inspection and repair procedure.

Using an 1/8

s Allen wrench with a 3/8s combination

wrench, remove drive clutch fly weights.

Note

direction of weight pin with nut on trailing side.
Inspect each weight. Surface should be smooth, with
no waves or galling. Place bolt inside weight to check
flyweight bushing and pin surface for wear.

NOTE: The weight bushing is not a service part and both
weight and pin must be replaced if worn.

Inspect all rollers, bushings and roller pins by pulling
a flat metal rod across the roller. Roller can also be
inspected by rolling with finger to feel for flat spots,
roughness, or loose bushing. Also inspect to see if
roller and bushing are separating. Bushing must fit
tightly in roller. Replace roller and pin if roller fails to
roll smoothly (flat spots) or if bushing is loose.

Note bolt
Direction

Direction
of rotation

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