Polaris 2012 Sportsman Forest 500 International, Service Manual

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6.5
CLUTCHING
6
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Overheating / Diagnosis
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 vehicle
should be operated in Low when plowing or pulling heavy loads, or if extended low speed
operation is anticipated.
IMPORTANT: Using High for heavy loads, hilly terrain, or in wet, muddy conditions will increase the chance of
drive belt burning.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS
Possible Causes Solutions / What to do
Loading the vehicle into a truck or tall
trailer when in high range.
Shift transmission to Low during loading of the vehicle to prevent belt burning.
Starting out going up a steep incline from
a stopped position. When starting out on an incline, use Low, or dismount the vehicle 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. The use of Low is highly recommended
for cooler PVT operating temperatures and longer component life.
Insufficient warm-up of vehicles exposed
to low ambient temperatures.
Warm engine at least 5 min., then with transmission in neutral, advance
throttle to approx. 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.
Towing/Pushing at low RPM/low ground
speed.
Use Low only.
Plowing snow, dirt, etc./utility use. Use Low only.
Stuck in mud or snow.
Shift the transmission to Low, 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, carefully use fast, aggressive, brief 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 full throttle. Repeat several times as required. During this procedure,
the throttle should not be held at the full position for more than 10 seconds.
Clutch seals should be inspected for damage if repeated leaking occurs.
Clutch malfunction.
For inspection of clutch components, please contact your Polaris dealer. Shift
transmission to Low during loading of the vehicle to prevent belt burning.
Poor engine performance.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Contact
you dealer for further service information.
GENERAL RANGE OPERATION
GUIDELINES:
Low: Heavy pulling, basic operational speeds less than 7 MPH, riding
through rough terrain (swamps, mountains, ect.), low ground speeds.
High: High ground speeds, speeds above 7 MPH.