Problem, Cause And Remedy Chart - Polaris 2007 SPORTSMAN X2 800 Service Manual

Problem, Cause and Remedy Chart

S
ITUATION
-Wrong or broken drive clutch spring.
Engine RPM below
specified operating range
-Drive clutch shift weight too heavy.
although engine is
properly tuned.
-Driven clutch spring broken or installed wrong . -Replace spring; refer to proper installation location
-Drive clutch binding.
Erratic engine operating
-Belt worn unevenly - thin/burnt spots
RPM during acceleration
or load variations.
-Driven clutch malfunction.
-Sheave face grooved.
-Incorrect drive clutch spring (too high spring
rate).
-Drive clutch shift weights incorrect for
application (too light)
Engine RPM above
-Drive clutch binding.
specified operating range.
-Driven clutch binding.
-Converter sheaves greasy; belt slippage.
-Drive belt worn too narrow.
Harsh drive clutch
engagement.
-Excessive belt/sheave clearance with new belt.
-Wrong belt for application.
Drive belt turns over -Clutch alignment out of spec.
-Engine mount broken or loose
-Plugged air intake or outlet
-Belt slippage due to water, oil, grease, etc.,
rubbing on cover
PVT cover overheating
-Clutches or weight being applied to cover while
(melting)
in operation
-Use of High vs. low range
-Cover seals or ducts leaking
Water Ingestion
-Operator error
-Belt worn out
Belt Slipping -Water ingestion
-Belt contaminated with oil or grease
Table 6-2: Problem, Cause and Remedy
P C
OSSIBLE AUSE
CLUTCH SYSTEM
R
EMEDY
-Replace with recommended spring.
-Install correct shift weight kit to match engine
application.
a. Disassemble drive clutch; inspect shift weights for
wear and free operation.
Replace belt
a. Replace ramp buttons.
b. Inspect movable sheave for excessive bushing
-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
-Disassemble, clean, and inspect driven clutch, noting
worn sheave bushing and ramp buttons and helix
-Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
-Replace belt.
-Perform belt/sheave clearance adjustment with shim
washers 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 wet
terrain as outlined in Owner's Safety and Maintenance
-Find leak and repair as necessary.
-Instruct operator on guidelines for operation in wet
terrain as outlined in Owner's Safety and Maintenance
-Replace belt.
-Inspect and seal PVT system.
-Inspect and clean.
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