2007 Polaris Sportsman 700/800/800 X2 EFI Service Manual, Page 207Get this manual
CLUTCH SYSTEM Problem, Cause and Remedy Chart Table 6-2: Problem, Cause and Remedy
SITUATION POSSIBLE CAUSE REMEDY -Replace with recommended spring-Install correct shift weight kit to match engine application-Replace spring; refer to proper installation location aDisassemble drive clutch; inspect shift weights for wear and free operationReplace belt aReplace ramp buttonsbInspect 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 rollersReassemble 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 beltsheave clearance adjustment with shim washers beneath spider-Replace with correct belt-Adjust alignment offset-Inspectadjust or replace-Clear obstruction-Inspect systemCleanrepair or replace as necessarySeal PVT system ducts-Wrong or broken drive clutch springEngine RPM below specified operating range -Drive clutch shift weight too heavyalthough engine is properly tuned-Driven clutch spring broken or installed wrong -Drive clutch bindingErratic engine operating -Belt worn unevenlythinburnt 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 bindingspecified operating range-Driven clutch binding-Converter sheaves greasy; belt slippageHarsh drive clutch engagement-Drive belt worn too narrow-Excessive beltsheave clearance with new belt-Wrong belt for applicationDrive 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