Drive Clutch Spring Specifications - Polaris 2005 Sportsman MV7 Service Manual

DRIVE CLUTCH SPRING SPECIFICATIONS

The drive clutch spring has two
primary functions:
1. Controls clutch engagement
RPM. The springs which have a
higher rate when the clutch is in
neutral will increase
engagement RPM.
2. Controls the rate at which the
drive belt moves upward in the
drive clutch sheaves. This is
referred to as drive clutch upshift.
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
coil spring is subject to during
operation, it should
inspected for tolerance limits during
any clutch diagnosis or repair.
There are other components which
control upshift, but the spring is one of
the primary components in insuring
optimum performance.
important that the spring is of 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 component failure.
Measuring Spring Length: 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
NUMBER CODE
7041021 Plain
Black
7041022
7041063 Purple
7041132 White
7041168 Green
7041157 Blue/Green
300
280
260
clutch
240
220
200
180
160
140
120
always be
100
80
60
40
It is very
20
0
2.5
WIRE FREE LENGTH
DIAMETER
¦.125I
.157I 4.38I
.140I 4.25I
.168I 4.37I
.177I 2.92I
.177I 3.05I
.177I 2.53I
NEUTRAL
ATV TRAVEL
2.25 2.00 1.75
COMPRESSED SPRING LENGTH (INCHES)
Secondary Clutch Springs
PART DESCRIPTION
NUMBER
7041198 Red
Black 5- -coil
7041782
7041501 Gold 6- -coil
7041499 Silver
7041296 Blue
7041646 Silver/Blue
CLUTCH
FULL UPSHIFT
Green
7041168
Purple
7041063
White
7041132
Plain
7041021
Blue/Green
7041157
Black
7041022
1.50 1.25 1.19
6.9