Drive Clutch Spring Inspection; Shift Weight Inspection - Polaris Sportsman XP 1000 S 2020 Service Manual

DRIVE CLUTCH SPRING INSPECTION

IMPORTANT
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.
Check to see that spring coils are parallel to one another
using a straight-edge. Distortion of the spring indicates
stress fatigue, requiring replacement.
Measure the drive clutch spring height. Compare to
specification and replace if necessary.
MEASUREMENT
Drive Clutch Spring Height:
7043805: 2.865 in (72.771 mm)
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.

SHIFT WEIGHT INSPECTION

1. Remove all shift weight fasteners
2. Inspect the contact surface of each weight. The
surface should be smooth and free of dents or gall
marks.
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3. Inspect each pivot bore
galling. Also inspect each shift weight bushing for
wear and replace if necessary. If weights or bolts are
worn or broken, replace in sets of three with new bolts
and nuts.
IMPORTANT
The clutch assembly is a precisely balanced unit. Never
replace parts with used parts from another clutch
assembly.
NOTICE
A damaged shift weight is usually caused by a
damaged or stuck roller in the spider assembly. See
"Roller, Pin, and Thrust Washer Inspection" for more
information.
PVT SYSTEM
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and weights .
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and bolt for wear or
6.15
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