polaris sportsman 500 clutch spring

factionfx · #1 (**permalink**) 01-20-2012, 10:22 AM

Hi All,

I have a 2012 500 HO Sportsman and am wanting to swap out the primary clutch spring. I have had great luck with this when I installed an exhaust and front spring on a 2006 Trailblazer, so I am not interested in buying a $300 clutch kit.

#1, I have found out that the stock polaris spring number is 7041157

#2, I mostly trail ride with stock tires. I am making a dunes trip later this year and some extra bottom end wont hurt---> What new spring do you recommend?

#3 I stumbled across Aaen's website, on the right are the stock polaris springs that I know about. Aaen Performance - Polaris ATV Accessories I think the polaris yellow 7041102 would be a good start.

#4, what clutch puller do I need? Will this one work? Polaris ATV Primary Drive Clutch Puller Tool 550 850 Sportsman 800 RZR | eBay

If anybody has a link to the full spectrum of polaris ATV clutch springs matrix, that would be greatly appreciated!

Thanks!

Kevcules · #2 (**permalink**) 01-20-2012, 03:29 PM

If your just replacing the primary clutch spring, you don't need to remove the clutch assembly from the bike. Simply remove the outer cover and the spring is right there. If you have to remove the clutch with a puller , you could buy the proper tool (not much money) or if you're frugal like me , just find out the puller thread size , get a piece of threaded rod , cut to length and weld a nut on the end. I did one for my 01 500 sportsman HO which is 3/4" fine thread , works perfectly.

Kevin

factionfx · #3 (**permalink**) 01-20-2012, 08:13 PM

Thanks for the info! I've replaced the springs before, but the tool I had was crappy. I had never considered just doing it while it was on the bike (and removing the 3 bolts for the outer cover). Thanks!

factionfx · #4 (**permalink**) 01-20-2012, 08:16 PM

FYI, I talked with tech support at EPI today. He suggested the PATV1 Red clutch spring. He said it was the only one I would be happy with slash would be the correct application for my bike.

The spring is only $25 so I will give it a go. Sure beats $300 for a clutch kit.

Here is what he wrote back......>>>>>

Your stock spring (7041157) Blue/Green is Measured a 2.25’’ 10LBS and at 1.25’’ 110LBS
Our Red (PATV1) will be a good fit for your bike it will give it a round a 400rpm increase in stall and the top rpms will increase around 150 to 200 rpm
Our red is rated as follows 2.25’’ 54LBS and 1.25’’ 140LBS
This spring should give what you are asking for anymore questions come up let us know and we will do our best to answer them for you.

The red is the only one I would suggest for yours and really is the only one that is compatiable if your just changing the primary spring if any thing it will help with your belt life due to not easing into the gas and slightly engaging witch will burn the belt because its slipping at first. It will engage faster eliminating some of the slippage at the engagement.

<<<<<<<

Kevcules · #5 (**permalink**) 01-21-2012, 07:51 AM

Good to hear....maybe I should try that too....

Kevin

factionfx · #6 (**permalink**) 02-06-2012, 05:27 AM

Kevin,

#1, you were spot on about not needing to pull the clutch. Oh well, i have a nice new clutch puller

.

#2,this weekend was the first ride on the new clutch spring. It worked great. I've only ridden the bike twice so I can't tell you whether it gave it a huge amount of power, but I know it at least gave it some. Top speed per speedometer seems to be about 56, and I think it gets all the way up to 6800 RPM. I never took it that high for a sustained time before because it wasn't really broken in. It just now has 17 hrs on it.

FYI I torqued the clutch cover bolts at 12 ft lb, and the primary clutch retaining bolt at 40ft lb, per the spec.

I found the PATV1 for 25 shipped on Amazon through a third part.

Kevcules · #7 (**permalink**) 02-06-2012, 04:00 PM

Great news , I should look at changing my spring also... thanks for the update.

Kevin

factionfx · #8 (**permalink**) 02-06-2012, 04:42 PM

You're welcome. Enjoy!

mrbeach8600 · #9 (**permalink**) 02-18-2012, 05:42 AM

I am looking for a little more performance out of my sportsman also. Thanks for post. Reading these post have given me what info I needed to order and install. Hope it does give me a littler better performance and I hope helps give longer belt life

SledRacer112 · #10 (**permalink**) 02-18-2012, 07:13 PM

I don't mean to hijack thread, but can someone school me on this a bit? How do they compare as far as stock clutch with different spring vs whole new clutch kit?

For instance I'm running 27" XTR's on my 800...I was looking at the EPI Sport Utilty kit...but if I were to just buy a new spring to put in the stock clutch what color would give me the best outcome?

Sorry for hijack!