2004 Polaris Touring Service Manual, Page 181Get this manual
CLUTCHING DriveDriven Clutches Troubleshooting
SYMPTOMS Harsh drive clutch engagement PROBABLE CAUSE -Drive belt worn too narrow -Excessive belt to sheave clearance with new belt (high performance version without detente shift weight) -Wrong belt for application -Clutch alignment out of spec -Engine mount broken or loose -Driven clutch sheaves have excessive runout, are bent or damaged -Replace -Perform belt to sheave clearance adjustment with shim washers beneath spider -Replace -Adjust alignment offset -Inspect, adjust or replace -Measurement should be taken .25 in from outer circumference on sheave faceMaximum allowable tolerance is .015 (.6 mm)-Inspectreplace -Install new buttons or shim out existing buttons -Inspectreplace -Inspectadjust or replace -Inspectreplace -Inspectreplace Inspectadjust Inspectreplace -Add spider shim washers -Add driven washers -Improper driven clutch setup -Worn belt -Excessive belt deflection -Improper offsetalignment -Broken or misadjusted torque stop -Broken motor mount -Jackshaft bearing seizure -Reduce gear ratio (chaincase models) -Replace -Subtract driven clutch washers -Inspectadjust -Inspectadjustreplace -Inspectreplace -Replace REMEDY