Drive Clutch Service; Spring Specifications - Polaris Ranger RZR 800 Manual

DRIVE CLUTCH SERVICE

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 clutch 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 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 relaxation 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.
PART NUMBER
7041021
7041022
7041063
7041132
7041157
7041168
7043199
7043349
7043372
7043382
7043594
Primary Clutch Springs
COLOR CODE
Plain
Black
Purple
White
Blue / Green
Green
Blue / Red
Red / White
Red / Blue
Red / Green
Black
WIRE DIAMETER
.157"
.140"
.168"
.177"
.177"
.177"
.177"
.200"
.187"
.177"
.177"
CLUTCHING
Red/White
7043349
Red/Blue
7043372
Red/Green
7043382
Blue/Red
7043199
Black
7043594
FREE LENGTH ± .125"
4.38"
4.25"
4.37"
2.92"
2.53"
3.05"
2.53"
2.58"
2.56"
2.63"
2.80"
6.11
6