Polaris 2005 Sportsman MV7, Service Manual

Page: 167 / 312

CLUTCH
6.9
DRIVE CLUTCH SPRING SPECIFICATIONS
The drive clutch spring has two
primary functions:
1.
Controls clutch engagement
RPM. The springs which have a
higher rate when the clutch is in
neutral will increase clutch
engagement RPM.
2. Controls the rate at which the
drive belt moves upward in the
drive clutch sheaves. This is
referred to as drive clutch upshift.
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
coil spring is subject to during
operation, it should always be
inspected for tolerance limits during
any clutch diagnosis or repair.
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 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 component failure.
Measuring Spring Length: 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
)