Then you're using too thick of a steel washer compared to the thickness of the brass washer for it to do this in this short period of time. If damaged the cup needs to be replaced.5131646 Polaris | eBay Plus you didn't mention it,but the fiber washer behind the one way needs to be replaced at the same time the "cup" washer is replaced.Then check with a feeler gauge as to the clearance between the one way bearing and inner sheath. Max is .020,but with everything right you shouldn't have more than .010 or so. Plus just make sure the one way bearing turns smoothly. If it's jumpy or not smooth turning, then the one way needs to have a thin film of grease on the shaft or it needs to be replaced also.

 

yes, the steel replacement washer was roughly .010" thicker and the fiber washer was replaced the first time. With the new spacer and brass washer, play was under .020".

 

Then if the cup is damaged replace it as cheap as they are,cut down on the size of the steel washer to just a tad oversize of the brass washer thickness.Check out the one way bearing itself. They don't last forever. Using the brass washer again on these is just trouble as I had the same problem on these models.That's when I talked to a Polaris engineer about the brass washers wearing so fast and he told me to use steel.Worked out great on the ones I had to do with no problems or come backs. This is the main pressure area and wear point on the one way when you torque the spider back down to 200 foot pounds.Don't forget about aligning the rear clutch to the front again.OR if you don't want to do it that way,get a new spacer(cup) and use the brass washer and see how it works then.