Snowmobile Polaris (2006 year). Manual - part 40

7.14

CLUTCHING

removed.

2.

Install the head of the weight pin (12) so that it is on the leading side of rotation. This will orientate the nut (11) on the trailing
side of rotation.

3.

Torque weight pin to 30 in-lb (3Nm).

4.

Place the moveable sheave (8) onto the stationary sheave (10).

5.

Place the same number of spacers (18) under the stepped washer (17) 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 7.15

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 (3) onto the clutch and torque the cover fasteners (2) to 90 in-lb (10Nm).

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

DRIVE CLUTCH SPIDER REMOVAL/INSTALLATION

ROLLER REMOVAL

1.

With the spider in a vise start removing the spider buttons (1) by drilling a 0.18" hole in the center of a button on one side of
the spider.

2.

Place spider (6) 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 (4) out.

4.

Remove shims (2) (if any are installed) and note their location.

5.

Flip the spider over and tap out the holed button.

A

E

C

B

F

G

H

L

K

D

7.15

CLUTCHING

ROLLER INSTALLATION

1.

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.

2.

Drive pin into the spider leg.100" -.125" (0.25 - 0.32cm)
beyond the first land of the spider leg (8).

3.

Install one washer (3) on the portion of the pin that is
protruding from the spider leg.

4.

Install new buttons into the spider

5.

Place roller (5) in spider leg and center it on the pin.

6.

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

7.

Place the spider on a vise.

8.

Install pin centering tool (PN 2870401).

9.

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

10. Repeat this for each roller.

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

installed (9) and record the measurement. Specification for
the width of the spider with buttons installed is 1.496"
(37.99mm).

12. Measure the width of the moveable sheave towers (10) and

record the measurement. Specification for the width of the
opening of the moveable sheave towers are 1.50"
(38.1mm).

13. 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 INDEXING

NOTE:  Spider indexing effects belt to sheave 
clearance and clutch balance. Please read all 
procedures before proceeding.

1.

Remove and Disassemble clutch See “DRIVE CLUTCH
DISASSEMBLY” on page 7.13

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 top of the spacer stack (B).

For example: If belt to sheave clearance is 0.020” too large, 
removing one 0.020 shim will position the movable sheave 
closer to the fixed sheave reducing belt to sheave clearance by 
0.020".

3.

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

       PN 5210754.050" (1.3mm)

       PN 5210753.032" (.8mm)

7.16

CLUTCHING

       PN 5210752.020" (.5mm)

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.

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 (D). For EXAMPLE: 0.020" or 0.032" (0.5 
- 0.8mm) washer removed - re-index spider clockwise 1/3 
turn.

NOTE:  Alignment marks on the sheaves should be 
with in 1" (.25mm) after final assembly and torquing.

SPRING 
FREE 

LENGTH

Maximum 
efficiency of the 
variable speed 
drive system is 
dependent upon 
many factors. 
Included in these 
are clutch offset 
and alignment, 

belt tension, belt to sheave clearance, and internal condition of 
the drive and driven clutch components. One of the most 
critical and easily serviced parts is the drive clutch spring. Due 
to the severe stress the spring is subject to during operation, it 
should always be inspected and checked for tolerance limits 
during any clutch operation diagnosis or repair.

With the spring resting on a flat surface, measure free length 
from outer coil surfaces as shown. Refer to the chart above for 
specific free length measurements and tolerances.

In addition to proper free length, the spring coils should be 
parallel to one another when placed on a flat surface. 
Distortion of the spring indicates stress fatigue. Replacement 
is required.

New springs that are introduced will be black in color with the 
last four digits of the spring part number, and the load rating in 
white ink on the outer diameter of the spring located and the 
mid height of the spring.

EXAMPLE: Spring PN 7042287 has a load rating of 110/290. 
The designation printed on the spring would be “2287 110/
290”.

CAUTION

Never shim a drive clutch spring to increase its compression 

rate. This may result in complete stacking of the coils and 

subsequent clutch cover failure

Table 7-4: Drive Clutch Springs

PART 

NUMBER

COLOR

WIRE 

DIAMETER 

(inches)

FREE LENGTH 

+/-.125”

FORCE 

LBS.@2.50” - 

1.19” (+/- 12 

LBS.)

LOAD 

RATE 

(lbs./

inch)

7041021

No paint color

.157”

4.14

70-130

44

7041022

Black

.140”

4.25”

44-77

25

7041063

Purple

.168

4.37

75-135

53

7041062

Silver

.207

3.12

75-243

151

7041065

Pink

.177

4.69

112-200

64

7041060

Orange

.196

3.37

70-199

98

7.17

CLUTCHING

7041083

Red

.192

3.77

120-245

94

7041102

Yellow

.192

2.92

44-185

105

7041061

Brown

.200

3.14

69-212

109

7041132

White

.177

2.92

34-141

81

7041168

Green

.177

3.05

42-142

76

7041148

Gold

.207

3.25

100-275

133

7041150

Red/White

.192

3.59

100-220

91

7041286

Silver/Gold

.218

3.05

77-240

163

7041080

Blue

.207

3.55

120-300

137

7041781

Dark Blue/White

.225

3.42

120-310

145

7041945

Almond

.218

3.65

140-330

145

7041645

Almond/Gold

.207

4.00

150-290

107

7041818

Black/White

.218

3.52

140-320

137

7041816

Almond/Black

.200

3.75

165-310

111

7041922

Almond/Blue

.218

3.75

150-310

122

7041988

Almond/Red

.207

4.27

165-310

110

7042083

Black/Green

.218

3.38

120-340

168

7043076

Black - 3076

.225

2.67

40-340

229

7043120

Black - 3120

.225

2.78

60-340

213

7043077

Black - 3077

.255

2.90

80-340

198

7043121

Black - 3121

.255

3.05

100-340

183

7042287

Black - 2287

.207

3.40

110-290

137

Table 7-4: Drive Clutch Springs

PART 

NUMBER

COLOR

WIRE 

DIAMETER 

(inches)

FREE LENGTH 

+/-.125”

FORCE 

LBS.@2.50” - 

1.19” (+/- 12 

LBS.)

LOAD 

RATE 

(lbs./

inch)