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(This is a post made earlier to PRC by Hoseclamp)
Since I had my primary all apart for more machining, I figured I'd do a quick step by step for those looking at improving the engagement and belt grip of their primary clutch.
Stock Polaris primary
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Before removing anything, mark the clutch cover and the clutch so you know how to line it up the same when re-assembling. You don't want to compromise the balance. I've always seen in the past Polaris marks the cover and clutch with an "X", so you know what lines up. Mine this time around did not, so to play it safe, mark it.
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You need to brace the primary to keep it from spinning. I'm using a hammer with a rubber handle. The rubber on the handle won't damage the primary when loosening or tightening the bolts.
![]()
First, break the center 5/8" bolt loose
![]()
Then, the 3/8" bolts
![]()
Remove all the 3/8" bolts so all the tension sits on the center bolt.
The spring pressure won't be much so you don't have to worry about the cover flying off and smashing your jaw. Here's the center bolt.
![]()
Keep a close eye on all the hardware on the center bolt, you don't want to lose anything, and you want it all to stay in order. I have an extra washer on mine with a larger diameter. This keeps my primary closer more, making less lag time on enagement.
The stock spring, a blue/green Polaris. Rater 16/120. Weak engagement, I hate this spring.
![]()
A replacement spring, a white Polaris. Rated 35-140, part # 7041132
![]()
This spring will raise engagement approx 400rpm, will give you much better belt grip, and should put you right on 6,000-6,200rpm, where you should be with your 500 Polaris.
Putting the cover back on can be alot of fun with only two hands. Luckily the white Polaris spring isn't so stiff it could hurt you on the install. Keep your center bolt near by, you want to install it quickly when the time comes.
Push the cover down with both hands all the way, make sure you're lined up. The center bushing will lock itself on the center shaft when holding it with only one hand now due to the "twisting" action.
![]()
Now install the center bolt, not all the way though.
You now want to install the 3/8" bolts.
![]()
With all 6 bolts installed, you'll snug down the center bolt and it will be 100% lined up now. You can see the 6 bolts are all sticking out a bit, do those next.
![]()
I haven't torqued my center bolts or cover bolts before, I always go by "feel" The primary is a soft magnesium, I'd rather feel it snug then possibly my torque wrench fails and I strip the cover bolts.
![]()
The center bolt you can torque, I don't remember the rated torque though. 40-50lbs would be sufficient.
Now, fire her up, let her warm up for a minute or two, rev it a few times
![]()
You want to visually check you're getting full travel now. Sometimes a spring will bind and you'll be scratching your head about why you're only getting 25mph out of a freshly tuned cvt. The paint can be too thick, or it was just a poor quality spring. This one is working just fine.
Belt goes in
![]()
Again, rev her up, make sure there's full travel.
![]()
When complete, enjoy a well deserved refreshment!!!
[img:8c597b326e]ht
Since I had my primary all apart for more machining, I figured I'd do a quick step by step for those looking at improving the engagement and belt grip of their primary clutch.
Stock Polaris primary
Before removing anything, mark the clutch cover and the clutch so you know how to line it up the same when re-assembling. You don't want to compromise the balance. I've always seen in the past Polaris marks the cover and clutch with an "X", so you know what lines up. Mine this time around did not, so to play it safe, mark it.
You need to brace the primary to keep it from spinning. I'm using a hammer with a rubber handle. The rubber on the handle won't damage the primary when loosening or tightening the bolts.
First, break the center 5/8" bolt loose
Then, the 3/8" bolts
Remove all the 3/8" bolts so all the tension sits on the center bolt.
The spring pressure won't be much so you don't have to worry about the cover flying off and smashing your jaw. Here's the center bolt.
Keep a close eye on all the hardware on the center bolt, you don't want to lose anything, and you want it all to stay in order. I have an extra washer on mine with a larger diameter. This keeps my primary closer more, making less lag time on enagement.
The stock spring, a blue/green Polaris. Rater 16/120. Weak engagement, I hate this spring.
A replacement spring, a white Polaris. Rated 35-140, part # 7041132
This spring will raise engagement approx 400rpm, will give you much better belt grip, and should put you right on 6,000-6,200rpm, where you should be with your 500 Polaris.
Putting the cover back on can be alot of fun with only two hands. Luckily the white Polaris spring isn't so stiff it could hurt you on the install. Keep your center bolt near by, you want to install it quickly when the time comes.
Push the cover down with both hands all the way, make sure you're lined up. The center bushing will lock itself on the center shaft when holding it with only one hand now due to the "twisting" action.
Now install the center bolt, not all the way though.
You now want to install the 3/8" bolts.
With all 6 bolts installed, you'll snug down the center bolt and it will be 100% lined up now. You can see the 6 bolts are all sticking out a bit, do those next.
I haven't torqued my center bolts or cover bolts before, I always go by "feel" The primary is a soft magnesium, I'd rather feel it snug then possibly my torque wrench fails and I strip the cover bolts.
The center bolt you can torque, I don't remember the rated torque though. 40-50lbs would be sufficient.
Now, fire her up, let her warm up for a minute or two, rev it a few times
You want to visually check you're getting full travel now. Sometimes a spring will bind and you'll be scratching your head about why you're only getting 25mph out of a freshly tuned cvt. The paint can be too thick, or it was just a poor quality spring. This one is working just fine.
Belt goes in
Again, rev her up, make sure there's full travel.
When complete, enjoy a well deserved refreshment!!!
[img:8c597b326e]ht
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