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Snowmobile Polaris High Performance (2001 year). Manual - part 45

CLUTCHING

4.8

Drive Clutch Spring Data

PART NUMBER

COLOR CODE

WIRE DIAMETER

FREE LENGTH +/-

.125

〉

Force lbs. @

2.50”--1.19

(+/-- 12lbs.)

7041021

Clear

.157

〉

4.38

〉

70--130

7041022

Black

.140

〉

4.25

〉

44--77

7041063

Purple

.168

〉

4.37

〉

75--135

7041062

Silver

.208

〉

3.12

〉

75--243

7041065

Pink

.177

〉

4.69

〉

112--200

7041060

Orange

.196

〉

3.37

〉

70--199

7041080

Blue/Gold

.207

〉

3.50

〉

120--300

7041083

Red

.192

〉

3.77

〉

120--245

7041102

Yellow

.192

〉

2.92

〉

44--185

7041061

Brown

.200

〉

3.06

〉

69--212

7041132

White

.177

〉

2.92

〉

34--141

7041168

Green

.177

〉

3.05

〉

42--142

7041148

Gold

.207

〉

3.25

〉

100--275

7041150

Red/White

.192

〉

3.59

〉

100--220

7041286

Silver/Gold

.218

〉

3.05

〉

77--240

7041080

Blue

.207

〉

3.55

〉

120--300

7041526

Dark Blue

.218

〉

3.52

〉

120--310

7041781

Dark Blue/White

.225

〉

3.52

〉

120--310

7041566

Almond

.207

〉

3.65

〉

140--330

7041645

Almond/Gold

.207

〉

4.00

〉

150--290

7041818

Black/White

.218

〉

3.52

〉

140--320

7041816

Almond/Black

.200

〉

3.75

〉

165--310

7041922

Almond/Blue

.218

〉

3.75

〉

150--310

7041988

Almond/Red

.207

〉

4.29

〉

165--310

CAUTION:

Never shim a drive clutch spring to increase its compres-
sion rate. This may result in complete stacking of the coils
and subsequent clutch cover failure.

Maximum efficiency of the variable speed drive system is
dependent upon many factors. Included in these are
converter offset and alignment, belt tension, belt to
sheave clearance, and internal condition of the drive and
driven clutch components. One of the most critical and
easily serviced parts is the drive clutch spring. Due to the
severe stress the spring is subject to during operation, it
should always be inspected and checked for tolerance
limits during any clutch operation diagnosis or repair.

With the spring resting on a flat surface, measure free
length from outer coil surfaces as shown. Refer to the
chart above for specific free length measurements and
tolerances.

In addition to proper free length, the spring coils should be
parallel to one another when placed on a flat surface. Dis-
tortion of the spring indicates stress fatigue. Replace-
ment is required.

Firm

Soft

CLUTCHING

4.9

Driven Clutch Springs

Part Number

Description

7041198

Red

7041782

Black-5 Coil

7041501

Gold-6 Coil

7041296

Blue

7041499

Silver

7041646

Silver/Blue

7042022

Blue/Orange

Driven Clutch Spring Data

Part Number

Description

Wire Dia.

Free

Length

Load at

2.50

〉

(lbs.)

Moment at



Rota-

tion (in #s)

Load at

1.375

〉

(lbs.)

Moment at

150



Rota-

tion (in #s)

7041198

Red

0.170

4.00

7041296

Blue

0.192

3.43

133

7041499

Silver

0.188

3.45

54.5

119

7041646

Silver/Blue

0.183

3.45

119

7041782

Black

0.177

3.60

7041501

Gold

0.188

3.60

7042022

Blue/Orange

0.192

3.50

133



150



Driven Spring Charts

Blue

Silver

Gold
and Black

Red

2.5

〉

1.375

〉

Compression Distance (in)

Load

ounds

100

120

140

Blue and

Blue/Orange

Silver or
Silver/Blue
Gold and Black

Red

Degrees of Rotation

Silver/Blue

Blue/Orange

CLUTCHING

4.10

Effects of Driven Clutch Spring

Increases in driven clutch spring preload will raise engine speed before the clutch starts shifting, allowing the
clutch to backshift more quickly. Decreases in driven clutch spring preload will result in faster upshift, but will also
slow backshift, thereby lowering engine RPM.

It is important to note that engine drive clutch calibration should be used to control engine speed rather than driven
clutch spring preload. Lowering RPMs by decreasing driven clutch spring preload will result in belt slippage on
acceleration. Increasing RPMs by increasing preload will result in excessive drive belt wear and decreased trans-
mission efficiency.

Refer to the chart on page 4.9 for available driven clutch springs. Experimenting with these springs will allow you
to find the most efficient combination of side pressure and back shifting for your application.

Spring tails in line - when installed
in clutch preload will cause tails
to be offset.

Spring tails offset - when installed
in clutch preload will cause tails
to be very close to being in line.

CLUTCHING

4.11

Effects of Driven Clutch Helix Ramp

A larger helix angle will allow the clutch to upshift at a lower engine RPM. Less side force will be exerted on the
moveable sheave and the clutch will upshift more rapidly. During backshift, a lesser helix angle will backshift more
easily and keep engine RPM higher. A larger helix angle will make it harder to downshift and will load the engine,
resulting in lower RPMs.

If all other variables are kept constant, a helix change with a lesser angle will result in slower upshift and faster
backshift. Engine RPM will remain higher. A helix change with a greater angle will result in faster upshift and
slower backshift. Engine RPM will be lower.

The drive clutch controls upshift, while the driven clutch controls backshift through the angle of the helix. The
factory helix will work well for most rugged cross country races, while a helix with a lesser angle may work better
for high speed ice cross country races.

Because backshifting is not important in drag races, most of these racers experiment with larger helix angles for
the fastest possible upshift. Multi-angle helixes are sometimes used by racers who need a good holeshot. A
multi-angle helix reduces to a smaller angle as the clutch shift out and RPM is increased to match the HP curve
of the engine. This is particularly true of engines with narrower powerbands.

Oval and snowcross racers need a good holeshot and a quicker backshift for good response out of the corners.
Helix angles may require a change depending on individual tracks. Depending on performance requirements,
continuous radius, compound angle, and straight angle helixes are available. Once again, experimentation is the
best method of determining what will work best for your application.

Continuous Radius

Compound Angle

Stopped

Fully shifted
out

Stopped

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