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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


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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is the part# for the white spring the same for the 07 700cc xp, and is that a sportsman spring
 

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The part # is the same for the 07's, its a Polaris part, I believe its used in several machines.
 

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thanks bro...
 

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I've thought about doing this mod, but I'm concerned whether it will make the rig more 'jumpy.' I do most of my riding in the woods at slow speeds and often need to crawl over trees, stumps, rocks, etc. Will this higher engagement RPM make my type of riding more difficult?
 

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Randy, I think it smooths it out. Its a 20 dollar deal, and an easy change, I would at least try it.
 

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More accurately it works like a torque converter, it lets your motor rev up more before it engages.
 

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Thanks for the great pics. I have been wanting to do this mod,
but for now I'll just go to the last step, refreshment
 

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Will this work on my '07 Ranger 4x4EFI (500cc)?

Thanks
 

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It helps all the Rangers from recent years.
 

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<blockquote id="quote"><font size="1" face="Verdana, Arial, Helvetica" id="quote">quote:<hr height="1" noshade id="quote">Originally posted by Bound4Dirt

Also, what do the numbers mean? They a lot here.
http://www.bikemanperformance.com/p...d=535&osCsid=65beda7b4ab11224abe30b8e51bd092c
<hr height="1" noshade id="quote"></font id="quote"></blockquote id="quote">
I believe they are weight/ pressure specs. Dale at Bikeman could tell you which one to use if you don't want to use the Polaris white spring.
 

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I would just like to add a special thanks to "Hoseclamp" for this post. I hope there's a RZR in you future, because I sure miss these (follow the picture) mods you did for us.

Mike, you are sorely missed here on the forum, and if you <u>never</u> plan on being here again, don't take a ride in a RZR[}:)][:D]
 

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<blockquote id="quote"><font size="1" face="Verdana, Arial, Helvetica" id="quote">quote:<hr height="1" noshade id="quote">Originally posted by Bound4Dirt

Also, what do the numbers mean? They a lot here.
http://www.bikemanperformance.com/p...d=535&osCsid=65beda7b4ab11224abe30b8e51bd092c
<hr height="1" noshade id="quote"></font id="quote"></blockquote id="quote">

These are the rates expressed in pounds at both the installed and compressed (primary clutch at full travel)
 

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I miss you guys, truely....................... yes something is in plan, heheheheh!
 

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<blockquote id="quote"><font size="1" face="Verdana, Arial, Helvetica" id="quote">quote:<hr height="1" noshade id="quote">Originally posted by hoseclamp

I miss you guys, truely....................... yes something is in plan, heheheheh!
<hr height="1" noshade id="quote"></font id="quote"></blockquote id="quote">

Welcome back Mike.................do tell, whats up (BLAZE II)? We sure could use a clutch expert around here.
 

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Mike:

You have been missed. <font color="blue"><font size="4">WELCOME HOME!</font id="size4"></font id="blue"> [:eek:)]

Any chance we could transplant a 100CID Victory motorcycle engine in my Ranger? [:D][:D]
 
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