2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 201Get this manual
DRIVE CLUTCH ASSEMBLY
NOTE: It is important that the same number and thickness of washers are reinstalled beneath the spider during assemblyThe Teflon bushings are self-lubricatingDo not apply oil or grease to the bushings1Reassemble drive clutch in the following sequenceBe sure the "X", or the marks that were made earlier, are aligned during each phase of assemblya) "X", or the marks that were made earlier, on cover b) spider, making sure spacer washers are installed underneath spider and positioned properly in recess c) "X", or the marks that were made earlier, under weight 2Install moveable sheave onto fixed sheave3Install spider spacersUse same quantity and thickness as were removed4Compress 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 sheave5Torque spider to specification using the holding fixture and spider toolTorque with smooth motion to avoid damage to the stationary sheaveRefer to page 6.1 for torque specificationCAUTION: Be sure the spider spacer washers are fully seated in the recessed area in the spiderAny misalignment will alter clutch balanceInverting the clutch while initially tightening the spider will help position the washers