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Snowmobile Polaris PRO X (2003 year). Manual - part 35

Firm

Soft

CLUTCHING

4.8

Driven Clutch Springs (Polaris Clutch)

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

s (lbs.)

Moment at

q Rota-

tion (in #s)

Load at

1.375

(lbs.)

Moment at

150

q 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

4.9

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

4.10

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

CLUTCHING

4.11

Helix Angles and Effects (Polaris Clutch)

The driven clutch helix was selected for overall performance in relation to the other driven system components. In
fine tuning situations requiring a slight adjustment of engine operating RPM or improved backshift, we
recommend trying a helix change before changing other components.

The helix spring should always be adjusted within its limits before a helix change is performed. The normal rate of
change between helix angle steps is 250 RPM under full throttle. This is approximately the same result as in going
from the No. 1 to No. 4 spring position. NOTE: Increasing spring tension increases engine RPM. RPM changes
may not be evident if other drive or driven clutch components are substandard.
On most models the production helix spring hole location is No. 2. Tension the spring 1/3 turn. Install helix key,
thrust washer and snap ring.

Polaris has several helix angles available for the driven clutch. Refer to the chart below for specific angle effects
and identification. See NOTE: below.

Description

Degrees

System Type

5130896

P85

34M*

5130751

P85

5130895

P85

36M*

5130717

P85

5130723

P85

5130724

P85

5130725

P85

5130726

P85

40-36*

5130898

40-36

P85

R1*

5131287

40-32

P85

R2*

5131288

42-32

P85

R3*

5131289

45-32

P85

R4*

5131290

50-32

P85

R5*

5131291

40-34

P85

R6*

5131292

42-34

P85

R7*

5131293

45-34

P85

R8*

5131294

50-34

P85

R9*

5131295

40-36

P85

R10*

5131296

42-36

P85

R11*

5131297

45-36

P85

R32*

5131623

50-34

P85

R12*

5131298

50-36

P85

R49

5133023

52--34

P85

T-1*

5131013

42-36-34

P85

36.5

5130383

36.5

P90

40-38-36

5131161

40-38-36

P90

38-36

5131162

38-36

P90

38-36-34

5131163

38-36-34

P90

5131164

P90

5131164

P90

* NOTE: All R-Series, Mod(M), T1, and 40-36 helix ramps are cut 0.060

s deeper in the snap ring pocket.

These are made so the driven clutch can open far enough for full shift out with wide 1 7/16

s belts.

If these helix ramps are used with narrow belts, 2 additional .030

s /.8 mm (PN 7556804) washers (for a total of

three) must be installed under the snap ring to prevent the belt from touching the inner hub at full shift which can
cause belt failure.

Wide belt models use only the existing washer under the snap ring.

NOTE: Always Install Snap Ring with
Chamfer Towards Helix (sharp edge out-
ward)

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