Polaris Discussions about Polaris ATVs.

Stupid mistake,Need help

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Old Aug 1, 2009 | 01:52 PM
  #1  
island hunter's Avatar
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Trailblazer
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Default Stupid mistake,Need help

I took my 03 400 sportsman secondary clutch apart to remove shim for belt deflection and i forgot to make marks on clutch to line it back up and when i put it back together,i put it back on quad and now i have no power to barely move quad.Is there an easy way to set it back,i turned it a third of a turn but still the same.Am i going to have to bring it to the dealer to fix this.
hope somebody can help.....
 
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Old Aug 1, 2009 | 04:35 PM
  #2  
old polaris tech's Avatar
Polaris ATV Expert
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From: North Texas
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Originally Posted by island hunter
I took my 03 400 sportsman secondary clutch apart to remove shim for belt deflection and i forgot to make marks on clutch to line it back up and when i put it back together,i put it back on quad and now i have no power to barely move quad.Is there an easy way to set it back,i turned it a third of a turn but still the same.Am i going to have to bring it to the dealer to fix this.
hope somebody can help.....
Install spring in #2 helix position,align WIDE spline opening with wide spline on shaft,push helix down and install other end of spring in #2 position in sheath. Push down slightly on helix on shaft,HOLD helix with your belly! HOLD bottom sheath while holding helix down and turn UPPER sheath 1/3 turn COUNTERCLOCKWISE (helix will turn also) Then have someone hold BOTH sheaths (or use c-clamps),helix SHOULD stay in place! Knock helix all the way down and install circlip. When you let go the clutch will spring back. Then check that you can hold top sheath and can turn bottom sheath,when you let go should snap back! Hope this helps OPT
 
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Old Aug 2, 2009 | 05:48 AM
  #3  
island hunter's Avatar
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Thanks alot OPT for the help.It worked like a charm.
What a difference removing one shim in the clutch can make.

I'm sure glad there's guys like you out there to help guys out when they get in a jam
Again thanks alot OPT
 
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