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Troubleshooting - Polaris RZR XP 1000 Service Manual

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TROUBLESHOOTING

SITUATION
PROBABLE CAUSE
Wrong or broken drive clutch spring.
Engine RPM
below specified
Drive clutch shift weight too heavy.
operating range,
although engine
Driven clutch spring broken or installed in
is properly tuned.
wrong helix location.
Drive clutch binding.
Erratic engine
operating RPM
during
Belt worn unevenly - thin / burnt spots.
acceleration or
load variations.
Driven clutch malfunction.
Sheave face grooved.
Incorrect drive clutch spring (too high of
rate).
Drive clutch shift weights incorrect for
application (too light).
Engine RPM
Drive clutch binding.
above specified
operating range.
Driven clutch binding.
Converter sheaves greasy; belt slipage.
Drive belt worn too narrow.
Harsh drive clutch
Excessive belt / sheave clearance with new
engagement.
belt.
Drive belt turns
Wrong belt for application.
over
Abuse (continued throttle application when
vehicle is stationary, excess load)
Belt burnt, thin
Dragging brake
spots
Slow, easy clutch engagement
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
REMEDY
Replace with recommended spring.
Install correct shift weight kit to match engine
application.
Replace spring; refer to proper installation
location.
Disassemble drive clutch; inspect shift weights
for wear and free operation.
Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
problem area.
Replace belt.
Replace ramp buttons.
Inspect movable sheave for excessive bushing
clearance.
Replace the clutch.
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 washers beneath spider.
Replace with correct belt.
Caution operator to operate machine within
guidelines.
Inspect brake system.
Fast, effective use of throttle for efficient
engagement.
PVT SYSTEM
5
5.37

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Rzr xp4 1000