Polaris 2005 Sportsman MV7 Service Manual page 186

CLUTCH
Engine RPM -Incorrect drive clutch spring (too high
above specified spring rate).
operating
range. -Drive clutch shift weights incorrect for ap-
plication (too light).
-Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slippage.
Harsh drive -Drive belt worn too narrow.
clutch engage-
ment. -Excessive belt/sheave clearance with new
belt.
Drive belt turns -Wrong belt for application.
over
-Clutch alignment out of spec.
-Engine mount broken or loose.
PVT cover -Plugged air intake or outlet
overheating
(melting) -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
Water ingestion -Cover seals or ducts leaking
-Operator error
Belt slippage -Belt worn out
-Water ingestion
-Belt contaminated with oil or grease
Belt burnt, thin -Abuse (continued throttle application when
spots vehicle is stationary, excess load)
-Dragging brake
-Slow, easy clutch engagement
PVT noise -Belt worn or separated, thin spots, loose
belt
-Broken or worn clutch components, cover
hitting clutches
Engagement -Thin spots on belt, worn belt
erratic or stabby
-Drive clutch bushings stick
6.28
-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.
-Replace belt.
-Perform belt/sheave clearance adjustment with shim wash-
ers beneath spider.
-Replace with correct belt.
-Adjust alignment offset.
-Inspect/adjust or replace.
-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.
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet terrain as
outlined in Owner's Safety and Maintenance Manual.
-Replace belt.
-Inspect and seal PVT system.
-Inspect and clean.
-Caution operator to operate machine within guidelines.
-Vehicle operated with park brake on. Inspect brake system.
-Instruct firm, effective use of throttle for efficient engage-
ment.
-Replace belt.
-Inspect and repair as necessary.
-Replace belt. Refer to belt burnt troubleshooting and instruct
operator.
-Inspect and repair clutches.