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6.36
CLUTCH SYSTEM
PVT TROUBLESHOOTING
Overheating
IMPORTANT: During routine maintenance or
whenever PVT system overheating is evident, it's
important to check the inlet and outlet ducting for
obstructions. Obstructions to air flow through the
ducts will significantly increase PVT system
operating temperatures. The ATV should be operated
in low range when pulling or plowing heavy loads, or
if extended low speed operation is anticipated.
General Range Operation Guidelines
LOW RANGE: Heavy pulling, basic operational speeds less
than 7 MPH, riding through rough terrain (swamps, mountains,
etc..), low ground speeds.
HIGH RANGE: High ground speeds, speeds above 7 MPH.
Table 6-1: Cause and Remedy
DIAGNOSIS OF CLUTCH DRIVE BELT & COVER RELATED ISSUES:
P
OSSIBLE CAUSES SOLUTIONS/WHAT TO DO
Loading the ATV into a pickup or
tall trailer when in high range.
Shift transmission to low range during loading of the ATV to prevent belt burning.
Starting out going up a steep
incline.
When starting out on an incline, use low range, or dismount the ATV after first applying the park
brake and perform the “K” turn.
Driving at low RPM or low
ground speed (at approximately
3-7 MPH).
Drive at higher speed or use Low Range. The use of Low Range is highly recommended for
cooler PVT operating temperatures and longer component life.
Insufficient warm-up of ATVs
exposed to low ambient
temperatures.
Warm engine at least 5 min., then with transmission in neutral, advance throttle to 1/8 throttle
in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Slow and easy clutch
engagement.
Fast, effective use of the throttle for efficient engagement. Continuous operation at the point of
engagement (initial vehicle movement) increases PVT temperatures and component wear.
Towing/Pushing at low RPM/low
ground speed.
Use Low Range only.
Plowing snow, dirt, etc./utility
use.
Use Low Range only.
Stuck in mud or snow.
Shift the transmission to Low Range, carefully use fast, aggressive throttle application to engage
clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.
Climbing over large objects from
a stopped position.
Shift the transmission to Low Range, carefully use fast, aggressive, throttle application to
engage clutch. Warning: Excessive throttle may cause loss of control and vehicle overturn.
Belt slippage from water or snow
ingestion into the PVT system.
Shift the transmission to neutral. Using the throttle, vary the engine rpm from idle to 3/4 throttle.
Engage transmission in the lowest possible range and test for belt slippage Repeat several times
as required. During this procedure, the throttle should not be held at the full position for more
than 10 seconds. PVT seals should be inspected for damage if repeated leaking occurs.
Clutch malfunction.
Inspection/repair of clutch components should be performed by a certified Polaris MSD
technician.