Polaris 2005 SPORTSMAN 500 Servise Manual page 156

CLUTCHING
PVT OVERHEATING/DIAGNOSIS
During routine maintenance or whenever PVT system overheating is evident, it's important to check the inlet
and outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT
system operating temperatures. The ATV should be operated in LOW RANGE when pulling or plowing heavy
loads, or if extended low speed operation is anticipated.
GENERAL RANGE OPERATION
GUIDELINES:
Diagnosis of Clutch Drive Belt & Cover Related Issues:
Possible Causes
Loading the ATV into a pickup or tall trailer
when in high range.
Starting out going up a steep incline.
Driving at low RPM or low ground speed
(at approximately 3--7 MPH).
Insufficient warm--up of ATVs exposed to
low ambient temperatures.
Slow and easy clutch engagement.
Towing/Pushing at low RPM/low ground
speed.
Plowing snow, dirt, etc./utility use.
Stuck in mud or snow.
Climbing over large objects from a
stopped position.
Belt slippage from water or snow ingestion
into the PVT system.
Clutch malfunction.
6.4
Low Range: Heavy pulling, basic operational speeds less
than 7 MPH, riding through rough terrain (swamps, mountains,
etc.), low ground speeds.
High Range: High ground speeds, speeds above 7 MPH.
Solutions/What to do
Shift transmission to low range during loading of the ATV to
prevent belt burning.
When starting out on an incline, use low range, or dismount the
ATV after first applying the park brake and perform the "K"
turn.
Drive at higher speed or use Low Range. The use of Low
Range is highly recommended for cooler PVT operating tem-
peratures and longer component life.
Warm engine at least 5 min., then with transmission in neutral,
advance throttle to approx. 1/8 throttle in short bursts, 5 to 7
times. The belt will become more flexible and prevent belt
burning.
Fast, effective use of the throttle for efficient engagement.
Continuous operation at the point of engagement (initial vehicle
movement) increases PVT temperatures and component wear.
Use Low Range only.
Use Low Range only.
Shift the transmission to Low Range, carefully use fast,
aggressive throttle application to engage clutch. Warning:
Excessive throttle may cause loss of control and vehicle
overturn.
Shift the transmission to Low Range, carefully use fast,
aggressive, throttle application to engage clutch. Warning:
Excessive throttle may cause loss of control and vehicle
overturn.
Shift the transmission to neutral. Using the throttle, vary the
engine rpm from idle to 3/4 throttle. Engage transmission in
the lowest possible range and test for belt slippage Repeat
several times as required. During this procedure, the
throttle should not be held at the full position for more
than 10 seconds. PVT seals should be inspected for damage
if repeated leaking occurs.
Inspection/repair of clutch components should be performed by
a certified Polaris MSD techinician.