Polaris SPORTSMAN 400 2003, Service Manual, Page: 163 / 274

CLUTCH
6.32
8. Remove nut (C) (left hand thread) from puller rod
and set aside. 9. Remove installation tool and clutch sheave from
puller.
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
wrong .
-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 accelera-
tion or load vari-
ations. -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.
-Replace the clutch.
Engine RPM
above specified
operating
range. -Incorrect drive clutch spring (too high
spring rate).
-Drive clutch shift weights incorrect for ap-
plication (too light).
-Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slippage.
-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 engage-
ment. -Drive belt worn too narrow.
-Excessive belt/sheave clearance with new
belt.
-Replace belt.
-Perform belt/sheave clearance adjustment with shim wash-
ers 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 alignment offset.
-Inspect/adjust or replace.
PVT cover
overheating
(melting) -Plugged air intake or outlet
-Belt slippage due to water, oil, grease,
etc., rubbing on cover
-Clutches or weight being applied to cover
while in operation
-Use of High vs. low range
-Clear obstruction.
-Inspect system. Clean , repair or replace as necessary.
Seal PVT system ducts.
-Remove weight. Inform operator.
-Instruct operator on guidelines for operation in proper driving
range for different terrain as outlined in Owner’s Safety and
Maintenance Manual.
Water ingestion -Cover seals or ducts leaking
-Operator error
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet terrain as
outlined in Owner’s Safety and Maintenance Manual.
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