Clutches Troubleshooting - Polaris Magnum 2x4 Service Manual

Situation Probable Cause
Engine RPM -Wrong or broken drive clutch spring.
below specified
operating
-Drive clutch shift weight too heavy.
range, although
engine is prop- -Driven clutch spring broken or installed in
erly tuned. wrong helix location.
-Converter sheaves greasy; belt slippage.
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.
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
Water ingestion -Cover seals or ducts leaking
Belt slippage
-Belt worn out
-Belt deflection excessive
-Water ingestion
-Belt contaminated with oil or grease
Belt burnt, thin
-Abuse (continued throttle application when
spots
vehicle is stationary, excess load
-Dragging brake
PVT noise
-Belt worn or separated, thin spots, loose
belt (too much deflection)
-Broken or worn clutch components, cover
hitting clutches
Engagement
-Thin spots on belt, worn belt
erratic or stabby
-Drive clutch bushings stick
Polaris Industries Inc.
6.39
CLUTCHES
Troubleshooting
Remedy
-Replace with recommended spring.
-Install correct shift weight kit to match engine application.
-Replace spring; refer to proper installation location.
-Install new belt and/or adjust belt tension.
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
buttons. 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.
-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.
-Remove weight. Inform operator.
-Find leak and repair as necessary.
-Replace belt.
-Adjust belt deflection.
-Inspect and seal PVT system.
-Inspect and clean.
-Caution operator to use low gear when pulling heavy loads,
and operate machine within guidelines.
-Vehicle operated with park brake on. Inspect brake system.
-Replace or adjust belt.
-Inspect and repair as necessary.
-Replace belt. Adjust belt deflection.
-Inspect and repair clutches.
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