2005 Polaris Sportsman 400/500 Service Manual, Page 161Get this manual
CLUTCHING
SHIFT WEIGHT INSPECTION
1Inspect as shown, using clutch holding tool to compress the moveable sheaveThe contact surface of the weight should be smooth and free of dents or gall marksRemove shift weight bolts and weights
BUTTON TO TOWER CLEARANCE INSPECTION
1Inspect for any clearance between spider button to towerIf clearance exists, replace all buttons and inspect surface of towersSee Spider Removal next page
Button to Tower Clearance: .000.001I 2Inspect sheave surfacesReplace the entire clutch as an assembly if worn, damaged or crackedBroken Worn Good
Inspect the weight pivot bore and pivot bolts for wear or gallingIf weights or bolts are worn or broken, replace in sets of three with new boltsNOTE: damaged shift weight is usually caused by damaged or stuck roller in the spider assemblySee roller inspection, Page 6.12WARNING