Drive Clutch Spring Specifications - Polaris Sportsman 400 Service Manual

CLUTCH

DRIVE CLUTCH SPRING SPECIFICATIONS

The drive clutch spring has two prima-
ry functions:
1. To control clutch engagement
RPM. The springs which have a
higher rate when the clutch is in
neutral will increase
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 im-
portant 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 stress the
spring is subject to during operation, it
should always be inspected for toler-
ance 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.
PART NUMBER COLOR
CODE
7041021 Plain
7041022 Black
7041063 Purple
7041061 Brown
7041132 White
7041168 Green
7041148 Gold
7041150 Red/White
7041157 Blue/Green
7041653 White/Yellow
6.10
- projex@inbox.lv -
NEUTRAL
300
280
260
clutch
240
220
200
180
160
140
120
100
80
60
40
20
0
2.5 2.25
COMPRESSED SPRING LENGTH (INCHES)
WIRE FREE LENGTH
DIAMETER ¦.125I
.157I 4.38I
.140I 4.25I
.168I 4.37I
.200I 3.06I
.177I 2.92I
.177I 3.05I
.207I 3.25I
.192I 3.59I
.177I 2.53I
.187I 4.18I
FULL UPSHIFT
ATV TRAVEL
2.00 1.75 1.50
Blue/Blue-
Gold
7041080
Gold
7041148
Silver
7041062
Red
7041083
Red/White
7041150
Brown
7041061
Orange
7041060
Pink
7041065
Yellow
7041102
Green
7041168
Purple
7041063
White
7041132
Plain
7041021
Blue/Green
7041157
Black
7041022
1.25 1.19