Polaris INDY TRAIL RMK Service Manual page 182

PART NUMBER
7041021
7041022
7041063
7041062
7041065
7041060
7041080
7041083
7041102
7041061
7041132
7041168
7041148
7041150
7041286
7041080
7041526
7041781
7041566
7041645
7041818
7041816
7041922
7041988
7042083
CAUTION:
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.
Maximum efficiency of the variable speed drive system is dependent upon many factors. Included in these are
converter offset and alignment, belt tension, belt to sheave clearance, and internal condition of the drive and driv-
en clutch components. One of the most critical and easily serviced parts is the drive clutch spring. Due to the
severe stress the spring is subject to during operation, it should always be inspected and checked for tolerance
limits during any clutch operation diagnosis or repair.
With the spring resting on a flat surface, measure free
length from outer coil surfaces as shown. Refer to the
chart above for specific free length measurements and
tolerances.
In addition to proper free length, the spring coils should
be parallel to one another when placed on a flat sur-
face. Distortion of the spring indicates stress fatigue.
Replacement is required.
COLOR CODE WIRE DIAMETER
Clear
Black
Purple
Silver
Pink
Orange
Blue/Gold
Red
Yellow
Brown
White
Green
Gold
Red/White
Silver/Gold
Blue
Dark Blue
Dark Blue/White
Almond
Almond/Gold
Black/White
Almond/Black
Almond/Blue
Almond/Red
Black/Green
DRIVE / DRIVEN CLUTCHES
FREE LENGTH +/-
.125²
.157² 4.38²
.140² 4.25²
.168² 4.37²
.208² 3.12²
.177² 4.69²
.196² 3.37²
.207² 3.50²
.192² 3.77²
.192² 2.92²
.200² 3.06²
.177² 2.92²
.177² 3.05²
.207² 3.25²
.192² 3.59²
.218² 3.05²
.207² 3.55²
.218² 3.52²
.225² 3.52²
.207² 3.65²
.207² 4.00²
.218² 3.52²
.200² 3.75²
.218² 3.75²
.207² 4.29²
.218" 3.38"
Force lbs. @
2.50"- -1.19"
(+/- - 12lbs.)
70--130
44--77
75--135
75--243
112--200
70--199
120--300
120--245
44--185
69--212
34--141
42--142
100--275
100--220
77--240
120--300
120--310
120--310
140--330
150--290
140--320
165--310
150--310
165--310
120--340
5.5