Polaris 2003 Pro X - Clutch Troubleshooting

CLUTCHING
4.49
SYMPTOMS PROBABLE CAUSE REMEDY
Harsh drive clutch engage-
ment
-Drive belt worn too narrow
-Excessive belt to sheave clearance with
new belt (high performance version with-
out detent shift weight)
-Replace
-Perform belt to sheave clear-
ance adjustment with shim
washers beneath spider
Drive belt turn over -Wrong belt for application
-Clutch alignment out of spec
-Engine mount broken or loose
-Driven clutch sheaves have excessive
runout, are bent or damaged
-Replace
-Adjust alignment offset
-Inspect, adjust or replace
-Measurement should be tak-
en .25s in from outer circum-
ference on sheave face. Max-
imum allowable tolerance is
.015s (.6 mm).
Noise in drive system -Broken drive clutch components
-Excessive drive clutch button - tower
clearance
-Bearing failure/ chaincase, jackshaft or
front drive shaft
-Drive chain loose or worn, sprocket teeth
broken
-Driven clutch bushing worn excessively or
spring broken
-Drive chain adjustment too tight/too loose
-Drive belt surface flat spots
-Inspect/replace
-Install new buttons or shim
out existing buttons
-Inspect/replace
-Inspect/adjust or replace
-Inspect/replace
-Inspect/replace
Inspect/adjust
Inspect/replace
Over rev during initial accel-
eration or during heavy pulling
at low ground speeds.
Engine bogs after engage-
ment.
-Spider roller position remaining in detent
-Improper driven clutch setup
-Worn belt
-Excessive belt deflection
-Improper offset/alignment
-Broken or misadjusted torque stop
-Broken motor mount
-Jackshaft bearing seizure
-Add spider shim washers
-Add driven washers
-Reduce gear ratio (chaincase
models)
-Replace
-Subtract driven clutch wash-
ers
-Inspect/adjust
-Inspect/adjust/replace
-Inspect/replace
-Replace
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