Polaris Sportsman 800 EFI 4x4 2012 Service Manual page 232

CLUTCHING
3. Inspect cover bushing (A). The outer cover bushing
is manufactured with a Teflon coating. Wear is
determined by the amount of Teflon remaining on the
bushing.
Cover Bushing Inspection:
Replace the cover bushing if more
brass than Teflon™ is visible on
the bushing. Refer to bushing
replacement in this chapter.
4. Inspect area on shaft where bushing rides for wear,
galling, nicks, or scratches. Replace clutch assembly
if worn or damaged.
5. Remove and inspect the clutch spring. See "Drive
Clutch Spring Specifications" for spring inspection.
Drive Clutch Spring Inspection
6.16
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. Also check to
see that spring coils are parallel to one another.
Distortion of the spring indicates stress fatigue,
requiring replacement.
Drive Clutch Spring Specifications
Color
Free Length
Drive Clutch Spring Specifications
2012 Sportsman Big Boss 6x6 800 EFI
Color
Free Length
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
CAUTION
2012 Sportsman 800 EFI
Black
2.8" (71.12 mm)
Red / Blue
2.56" (65.024 mm)