Drive Clutch Spring Specifications - Polaris 2004-2005 Sportsman 6x6 Service Manual

DRIVE CLUTCH 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
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.
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 stress 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
NUMBER CODE
7041021 Plain
7041022 Black
7041063 Purple
7041132 White
7041168 Green
7041157 Blue/Green
6.8
300
280
260
clutch
240
220
200
180
160
140
It is very
120
100
80
60
40
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
7041782 Black 5- -coil
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