6.15
CLUTCHING
6
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Drive Clutch Spring Inspection
The drive clutch spring is one of the most critical
components of the PVT system. It is also one of the
easiest to service. Due to the severe relaxation the spring
is subject to during operation, it should always be
inspected for tolerance limits during any clutch operation
diagnosis or repair.
With the spring resting on a flat surface, measure its free
length from the outer coil surfaces. Also check to see that
spring coils are parallel to one another. Distortion of the
spring indicates stress fatigue, requiring replacement.
Shift Weight Inspection
1. Remove shift weight bolts and weights. Inspect the
contact surface of the weight. The surface should be
smooth and free of dents or gall marks. Inspect the
weight pivot bore and bolts for wear or galling. If
weights or bolts are worn or broken, replace in sets of
three with new bolts and nuts.
NOTE: A damaged shift weight is usually caused by
a damaged or stuck roller in the spider assembly.
See “Roller, Pin and Thrust Washer Inspection”.
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.
Drive Clutch Spring Specifications
2012 Sportsman 400
Color Blue / Grey
Free Length 2.55” (64.77 mm)
Drive Clutch Spring Specifications
2012 Sportsman 500 HO, Touring, Forest,
Tractor 500 EFI
Color Green / Blue
Free Length 2.53” (64.262 mm)
The clutch assembly is a precisely balanced
unit. Never replace parts with used parts from
another clutch assembly!
Inspect for
excessive wear
Inspect for
excessive wear
Inspect for
excessive wear
Bolt
Nut
Shift Weight
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