Drive Clutch Service; Spring Specifications - Polaris Ranger 500 2x4 2007 Service Manual

DRIVE CLUTCH SERVICE

Spring Specifications

The drive clutch spring has two primary functions:
1. To control clutch engagement RPM. The springs
which have a higher rate when the clutch is in neutral
will increase clutch engagement RPM.
2. To control the rate at which the drive belt moves
upward in the drive clutch sheaves. This is referred
to as drive clutch upshift.
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 the 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
cover failure.
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 relaxation the
spring is subject to during operation, it should always be inspected for
tolerance limits during any clutch operation diagnosis or repair.
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
PART
COLOR CODE
NUMBER
7041021 Plain
7041022 Black
7041063 Purple
7041132 White
7041168 Green
7041157 Blue/Green
WIRE FREE LENGTH
DIAMETER ± .125"
.157" 4.38"
.140" 4.25"
.168" 4.37"
.177" 2.92"
.177" 3.05"
.177" 2.53"
CLUTCHING
Secondary Clutch Springs
PART
DESCRIPTION
NUMBER
7041198 Red
7041782 Black 5-coil
7041501 Gold 6-coil
7041499 Silver
7041296 Blue
7041646 Silver/Blue
6
6.11