Polaris 2012 Sportsman Forest 500 International, Service Manual

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6.44
CLUTCHING
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
TROUBLESHOOTING
Situation Probable Cause Remedy
Engine RPM below
specified operating
range, although
engine is properly
tuned.
-Wrong or broken drive clutch spring.
-Drive clutch shift weight too heavy.
-Driven clutch spring broken or installed in wrong
helix location.
-Replace with recommended spring.
-Install correct shift weight kit to match engine
application.
-Replace spring; refer to proper installation location.
Erratic engine
operating RPM during
acceleration or load
variations.
-Drive clutch binding.
-Belt worn unevenly - thin / burnt spots.
-Driven clutch malfunction.
-Sheave face grooved.
A. Disassemble drive clutch; inspect shift weights for
wear and free operation.
B. Clean and polish stationary shaft hub; reassemble
clutch without spring to determine problem area.
Replace belt.
A. Replace ramp buttons.
B. Inspect movable sheave for excessive bushing
clearance.
-Replace the clutch.
Engine RPM above
specified operating
range.
-Incorrect drive clutch spring (too high spring rate).
-Drive clutch shift weights incorrect for application
(too light).
-Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slipage.
-Install correct recommended spring.
-Install correct recommended shift weights.
-Disassemble and clean clutch, inspecting shift weights
and rollers. Reassemble without the spring and move
sheaves through entire range to further determine
probable cause.
-Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix spring
location.
-Clean sheaves with denatured alcohol or brake cleaner,
install new belt.
Harsh drive clutch
engagement.
-Drive belt worn too narrow.
-Excessive belt / sheave clearance with new belt.
-Replace belt.
-Perform belt / sheave clearance adjustment with shim
washers beneath spider.
Drive belt turns over
-Wrong belt for application.
-Clutch alignment out of spec.
-Engine mount broken or loose.
-Replace with correct belt.
-Adjust clutch alignment.
-Inspect / adjust or replace.
Belt burnt, thin spots
-Abuse (continued throttle application when vehicle
is stationary, excess load)
-Dragging brake
-Slow, easy clutch engagement
-Caution operator to operate machine within guidelines.
-Vehicle operated with park brake on. Inspect brake
system.
-Fast, effective use of throttle for efficient engagement.