6.36
CLUTCH SYSTEM
PVT TROUBLESHOOTING
Overheating
IMPORTANT:
During routine maintenance or
whenever PVT system overheating is evident, it's
important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the
ducts will significantly increase PVT system
operating temperatures. The ATV should be operated
in low range when pulling or plowing heavy loads, or
if extended low speed operation is anticipated.
General Range Operation Guidelines
LOW RANGE:
Heavy pulling, basic operational speeds less
than 7 MPH, riding through rough terrain (swamps, mountains,
etc..), low ground speeds.
HIGH RANGE:
High ground speeds, speeds above 7 MPH.
Table 6-1: Cause and Remedy
D
IAGNOSIS
OF
C
LUTCH
D
RIVE
B
ELT
& C
OVER
R
ELATED
I
SSUES
:
P
OSSIBLE
C
AUSES
S
OLUTIONS
/W
HAT
TO
DO
Loading the ATV into a pickup or
tall trailer when in high range.
Shift transmission to low range during loading of the ATV to prevent belt burning.
Starting out going up a steep
incline.
When starting out on an incline, use low range, or dismount the ATV after first applying the park
brake and perform the “K” turn.
Driving at low RPM or low
ground speed (at approximately
3-7 MPH).
Drive at higher speed or use Low Range. The use of Low Range is highly recommended for
cooler PVT operating temperatures and longer component life.
Insufficient warm-up of ATVs
exposed to low ambient
temperatures.
Warm engine at least 5 min., then with transmission in neutral, advance throttle to 1/8 throttle
in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow and easy clutch
engagement.
Fast, effective use of the throttle for efficient engagement. Continuous operation at the point of
engagement (initial vehicle movement) increases PVT temperatures and component wear.
Towing/Pushing at low RPM/low
ground speed.
Use Low Range only.
Plowing snow, dirt, etc./utility
use.
Use Low Range only.
Stuck in mud or snow.
Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage
clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.
Climbing over large objects from
a stopped position.
Shift the transmission to Low Range, carefully use fast, aggressive, throttle application to
engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow
ingestion into the PVT system.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to 3/4 throttle.
Engage transmission in the lowest possible range and test for belt slippage Repeat several times
as required. During this procedure, the throttle should not be held at the full position for more
than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs.
Clutch malfunction.
Inspection/repair of clutch components should be performed by a certified Polaris MSD
technician.
Summary of Contents for 2007 Sportsman 450 EFI
Page 4: ...NOTES...
Page 20: ...NOTES GENERAL INFORMATION 1 16...
Page 27: ...2 7 MAINTENANCE 2 LUBRICATION FLUIDS SPORTSMAN Component Locations Sportsman Only Deluxe...
Page 58: ...2 38 MAINTENANCE Maintenance Schedule Service Date Hours Miles Service Performed Serviced By...
Page 78: ...3 20 ENGINE Cylinder Head Exploded View EH50PL EH50PL A...
Page 114: ...4 2 FUEL SYSTEM...
Page 139: ...4 27 FUEL INJECTION 4 EFI CIRCUIT Fuel Pump EFI CIRCUIT Ignition Coil...
Page 140: ...4 28 FUEL INJECTION EFI CIRCUIT Idle Air Control EFI CIRCUIT Throttle Position Sensor...
Page 142: ...4 30 FUEL INJECTION EFI CIRCUIT Air Temperature Sensor EFI CIRCUIT Malfunction Indicator Light...
Page 156: ...4 44 CARBURETOR SPORTSMAN 450 FUEL TANK FUEL DELIVERY SYSTEM Fuel System Exploded View...
Page 185: ...5 25 BODY STEERING SUSPENSION 5 X2 CARGO BOX Exploded View...
Page 188: ...5 28 BODY STEERING SUSPENSION X2 SEAT ASSEMBLY Exploded Views...
Page 268: ...NOTES FINAL DRIVE 7 40...
Page 270: ...8 2 GENERAL INFORMATION TRANSMISSION GENERAL Mounting Exploded View x2 x3 x4 x4 x2 x1 x1 x1...
Page 276: ...8 8 GENERAL INFORMATION 242 262 262 262 262 262...
Page 318: ...NOTES BRAKES 9 30...
Page 337: ...10 19 ELECTRICAL 10 ALL WHEEL DRIVE AND SPEEDOMETER TROUBLESHOOTING TEST 1 No All Wheel Drive...
Page 338: ...10 20 ELECTRICAL TEST 2 No Speedometer Display TEST 3 No Reverse Speed Limit...
Page 339: ...10 21 ELECTRICAL 10 TEST 4 No AWD Hub Safety Limit...
Page 341: ...10 23 ELECTRICAL 10 TEST 7 Fuel Gauge Display Not Working TEST 8 Shift Indicator Not Working...
Page 347: ...10 29 ELECTRICAL 10 Components of EFI Alternator and DC CDI Ignition System...
Page 348: ...10 30 ELECTRICAL EFI Ignition System Testing Flow Chart...
Page 353: ...10 35 ELECTRICAL 10 PDM...
Page 363: ...10 45 ELECTRICAL 10 Starter Lockout Diagram EFI Starter Lockout Diagram Sportsman 450...
Page 369: ...10 51 ELECTRICAL 10 BASIC WINCH WIRING Pre wired Models...
Page 370: ...10 52 ELECTRICAL TROUBLESHOOTING DIAGRAMS Power On EFI Start Circuit EFI To ECU Pin 12...
Page 371: ...10 53 ELECTRICAL 10 Ignition Coil EFI Fuel Pump EFI...
Page 372: ...10 54 ELECTRICAL Fan EFI Charging System EFI...
Page 373: ...10 55 ELECTRICAL 10 All Wheel Drive EFI Transmission Switch EFI...
Page 374: ...10 56 ELECTRICAL Reverse Override EFI Differential Solenoid X2...
Page 383: ...11 3 500 EFI INTERNATIONAL QUADRICYCLE 11 Exploded View Foot Brake Supply Hand Brake Supply...
Page 392: ...IX 6...
Page 393: ...WD 1 WIRE DIAGRAM 2007 SPORTSMAN ACTIVE DESCENT CONTROL ADC WIRE DIAGRAM...
Page 394: ...WD 2 WIRE DIAGRAM INTENTIONAL BLANK PAGE...
Page 395: ...WD 3 WIRE DIAGRAM 2007 SPORTSMAN 450 WIRE DIAGRAM...
Page 396: ...WD 4 WIRE DIAGRAM...
Page 397: ...WD 5 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI STANDARD WIRE DIAGRAM...
Page 398: ...WD 6 WIRE DIAGRAM...
Page 399: ...WD 7 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI DELUXE WIRE DIAGRAM...
Page 400: ...WD 8 WIRE DIAGRAM...
Page 401: ...WD 9 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI INTERNATIONAL WIRE DIAGRAM...
Page 402: ...WD 10 WIRE DIAGRAM...
Page 403: ...WD 11 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 WIRE DIAGRAM...
Page 404: ...WD 12 WIRE DIAGRAM...
Page 405: ...WD 13 WIRE DIAGRAM 2007 SPORTSMAN 500 EFI X2 QUADRICYCLE WIRE DIAGRAM...
Page 406: ...WD 14 WIRE DIAGRAM...