Pvt Overheating - Polaris Sportsman 400 Service Manual

CLUTCH

PVT OVERHEATING

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.
Clutch Drive Belt & Cover Related Issues: Diagnosis
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.
Poor engine performance.
GENERAL RANGE OPERATION
GUIDELINES:
6.4
- projex@inbox.lv -
Solutions/What to do
Shift transmission to low range during loading of the ATV to pre-
vent 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 temperatures and
longer component life.
Warm engine at least 5 min., then with transmission in neutral, ad-
vance 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.
Use Low Range only.
Use Low Range only.
Shift the transmission to Low Range, carefully use fast, aggressive
throttle application to engage clutch.
throttle may cause loss of control and vehicle overturn.
Shift the transmission to Low Range, carefully use fast, aggressive,
brief throttle application to engage clutch.
throttle may cause loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the engine
rpm from idle to full throttle. Repeat several times as required.
During this procedure, the throttle should not be held at the full
position for more than 10 seconds.
for damage if repeated leaking occurs.
For inspection of clutch components, please contact your Polaris
dealer.
Fouled plugs, foreign material in gas tank, fuel lines, or carburetor.
Contact you dealer for further service information.
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.
WARNING: Excessive
WARNING: Excessive
Clutch seals should be inspected