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CLUTCHES
Drive Clutch Spring Specifications
The drive clutch spring has two prima-
ry functions:
1. To control clutch engagement
RPM. The springs which have a
higher rate when the clutch is in
neutral
will
increase
clutch
NEUTRAL
300 ,.
·····································~i[·:······l!··'
. . . . . . . , . . . . . . . . . , ............ .
engagement RPM.
2. To control the rate at which the
drive belt moves upward in the
drive clutch sheaves.
This is
referred to as drive clutch upshift.
There are other components which
control upshift, but the spring is one of
the primary components in insuring
optimum performance. It is very im-
portant that the spring is of the correct
design and is in good condition.
CAUTION: Never shim a drive clutch
spring to increase its compression
280:
ur
c
z
260':"":::) .,.
g
240;
w
()
a:
220'
v
..
f! . .
200'
180'
1601
rate.
This may result in complete
80 '
stacking of the coils and subsequent
clutch cover failure.
The drive clutch spring is one of the
40 '
FULL
UPS~T
ATV TRAVEL .. .............
..........J:'?
O'v._ ... , . . . . . . , . . . ,
.c ...••. , ............ " ......... , ................... " ... , ...... , ............. ' .. ', ........... , .................... , ...... , ..••
most critical components of the PVT
system. It is also one of the easiest to
20
service. Due to the severe stress the
spring is subject to during operation, it
should always be inspected for toler-
ance limits during any clutch operation
diagnosis or repair.
2.5
2.25
2.00
1.75
1.50
COMPRESSED SPRING LENGTH (INCHES)
With the spring resting on a flat surface, measure its free
length from the outer coil surfaces as shown. Refer to
the spring specification chart for specific free length
measurements and tolerances. Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
PART NUMBER
COLOR
WIRE DI-
FREE LENGTH
CODE
AMETER
±.125/1
7041021
Plain
.157/1
4.38/1
7041022
Black
.140/1
4.25"
7041063
Purple
.168"
4.37"
7041062
Silver
.208/1
3.12/1
7041065
Pink
.177/1
4.69/1
7041060
Orange
.196/1
3.37"
7041080
Blue/Gold
.207/1
3.50/1
7041083
Red
.192/1
3.7T'
7041102
Yellow
.192/1
2.92/1
7041061
Brown
.200/1
3.06/1
7041132
White
.177"
2.92"
7041168
Green
.177"
3.05/1
7041148
Gold
.207"
3.25/1
7041150
Red/White
.192"
3.59/1
7041157
Blue/Green
.177"
2.53"
1.25 1.19
Blue/Blue·
Gold
7041080
Silver
7041062
7/96
6.4
Polaris Industries Inc.
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Troubleshooting
