Troubleshooting - Polaris SPORTSMAN 400 2003 Service Manual

CLUTCH
8. Remove nut (C) (left hand thread) from puller rod
and set aside.

TROUBLESHOOTING

Situation
Engine RPM -Wrong or broken drive clutch spring.
below specified
operating range -Drive clutch shift weight too heavy.
although engine
is properly -Driven clutch spring broken or installed
tuned. wrong .
Erratic engine -Drive clutch binding.
operating RPM
during accelera-
tion or load vari-
ations.
-Belt worn unevenly - thin/burnt spots
-Driven clutch malfunction.
-Sheave face grooved.
Engine RPM -Incorrect drive clutch spring (too high
above specified spring rate).
operating
range. -Drive clutch shift weights incorrect for ap-
plication (too light).
-Drive clutch binding.
-Driven clutch binding.
-Converter sheaves greasy; belt slippage.
Harsh drive -Drive belt worn too narrow.
clutch engage-
ment. -Excessive belt/sheave clearance with new
belt.
Drive belt turns -Wrong belt for application.
over
-Clutch alignment out of spec.
-Engine mount broken or loose.
PVT cover -Plugged air intake or outlet
overheating
(melting) -Belt slippage due to water, oil, grease,
etc., rubbing on cover
-Clutches or weight being applied to cover
while in operation
-Use of High vs. low range
Water ingestion -Cover seals or ducts leaking
-Operator error
6.32
Probable Cause
9. Remove installation tool and clutch sheave from
puller.
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.
-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 wash-
ers beneath spider.
-Replace with correct belt.
-Adjust alignment offset.
-Inspect/adjust or replace.
-Clear obstruction.
-Inspect system. Clean , repair or replace as necessary.
Seal PVT system ducts.
-Remove weight. Inform operator.
-Instruct operator on guidelines for operation in proper driving
range for different terrain as outlined in Owner's Safety and
Maintenance Manual.
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet terrain as
outlined in Owner's Safety and Maintenance Manual.