Troubleshooting - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

CLUTCHING

TROUBLESHOOTING

SITUATION PROBABLE CAUSE
-Wrong or broken drive clutch spring.
Engine RPM
below specified
-Drive clutch shift weight too heavy.
operating range,
although engine is
-Driven clutch spring broken or installed in
properly tuned.
wrong helix location.
-Drive clutch binding.
Erratic engine
-Belt worn unevenly - thin / burnt spots.
operating RPM
during acceleration
-Driven clutch malfunction.
or load variations.
-Sheave face grooved.
-Incorrect drive clutch spring (too high spring
rate).
-Drive clutch shift weights incorrect for
Engine RPM application (too light).
above specified
operating range. -Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slipage.
-Drive belt worn too narrow.
Harsh drive clutch
engagement.
-Excessive belt / sheave clearance with new
belt.
-Wrong belt for application.
Drive belt turns
-Clutch alignment out of spec.
over
-Engine mount broken or loose.
-Abuse (continued throttle application when
vehicle is stationary, excess load)
Belt burnt, thin
-Dragging brake
spots
-Slow, easy clutch engagement
6.48
REMEDY
-Replace with recommended spring.
-Install correct shift weight kit to match engine
application.
-Replace spring; refer to proper installation
location.
A. Disassemble drive clutch; inspect shift weights
for wear and free operation.
B. Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
problem area.
-Replace belt.
A. Replace ramp buttons.
B. 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.
-Adjust clutch alignment.
-Inspect / adjust or replace.
-Caution operator to operate machine within
guidelines.
-Vehicle operated with park brake on. Inspect
brake system.
-Fast, effective use of throttle for efficient
engagement.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.