Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 150 / 289

CLUTCH
6.8
DRIVE CLUTCH SPRING SPECIFICATIONS
The drive clutch spring has two
primary functions:
1.
To control clutch engagement
RPM. The springs which have a
higher rate when the clutch is in
neutral will increase clutch
engagement RPM.
2. To control the rate at which the
drive belt moves upward in the
drive clutch sheaves. This is
referred to as drive clutch upshift.
There are other components which
control upshift, but the spring is one of
the primary components in insuring
optimum performance. It is very
important that the spring is of the
correct design and is in good
condition.
CAUTION: Never shim a drive clutch
spring to increase its compression
rate. This may result in complete
stacking of the coils and subsequent
clutch cover failure.
The drive clutch spring is one of the
most critical components of the PVT
system. It is also one of the easiest to
service. Due to the severe stress the
spring is subject to during operation, it
should always be inspected for
tolerance limits during any clutch
operation diagnosis or repair.
With the spring resting on a flat surface, measure its free
length from the outer coil surfaces as shown. Refer to
the spring specification chart for specific free length
measurements and tolerances. Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
Primary Clutch Springs Secondary Clutch Springs
PART
NUMBER
COLOR
CODE
WIRE
DIAMETER
FREE LENGTH
¦
.125
I
PART
NUMBER
DESCRIPTION
7041021 Plain .157
I
4.38
I
7041198 Red
7041022 Black .140
I
4.25
I
7041782 Black 5--coil
7041063 Purple .168
I
4.37
I
7041501 Gold 6--coil
7041132 White .177
I
2.92
I
7041499 Silver
7041168 Green .177
I
3.05
I
7041296 Blue
7041157 Blue/Green .177
I
2.53
I
7041646 Silver/Blue
2.5 2.25 2.00 1.75 1.50 1.25 1.19
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
ATV TRAVEL
COMPRESSED SPRING LENGTH (INCHES)
Green
7041168
Purple
7041063
White
7041132
Plain
7041021
Black
7041022
NEUTRAL
FULL UPSHIFT
Blue/Green
7041157
F
O
RCE
(P
OUNDS
)