2003 Polaris Deep Snow Snowmobiles Service Manual, Page 205Get this manual
DRIVEDRIVEN CLUTCHES Clutch Offset Inspection
NOTE:Proper offset aligns the fixed sheaves of both clutch assembliesThis allows the clutches to be aligned throughout the shift range1Remove drive beltBelt deflection adjustments affect offsetSet belt deflection first2Install proper alignment tool, depending on type of clutch, as shown in Ill13Rear of driven clutch moveable sheave should just contact tool when clutch is pushed inward on jackshaftClutch Alignment (Tools) P902132 Offset (PN 2870914) P8558 Offset (PN 2870426) P90 Electric Start 1.28 Offset (straight edge) P85 Electric Start Offset (straight edge) Offset Alignment Tool OffsetNon-Electric Start Models 2132 Offset No gap at All models with P90 point "A" driven clutch 58 Offset All models with P85 driven clutch
NOTE: Up to .060 (1.5mm) air gap allowed at point "B"Up to .125 is acceptable on new machines
Clutch Offset Adjustment
1Determine direction driven clutch needs to be adjusted(Refer to Clutch Offset Inspection procedure above)2Remove driven clutch retaining bolt, and remove driven clutch3Add or take out washers on jackshaft between the driven clutch and jackshaft bearing to achieve proper offset4Most models require the driven clutch to float on the jackshaftAfter adjusting offset, add or remove shim washers from the retaining bolt to provide .030 -.060 (.75-1.5mm) of float on jackshaftThis will prevent side loads on the jackshaft bearingNOTE:On models with driven clutch snap ring retainer the clutch is mounted firmly on the shaft without floatNOTE:When checking electric start models, use straight edge as shown in Ill2If alignment is off, loosen the engine mounts and shift engine as required to obtain the proper offset and alignmentDriven Clutch Bolt Torque 12 ftlbs(16.6 Nm)