09 sportsman 550 xp engagement lag and clunk - Polaris ATV Forum
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post #1 of 21 (permalink) Old 06-27-2019, 12:37 PM Thread Starter
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09 sportsman 550 xp engagement lag and clunk

Got an 09 xp 550 that takes a second, and more throttle before it engages and starts to move. It also clunks a bit when it finally engages. Belt? Clutch? Any ideas?
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post #2 of 21 (permalink) Old 06-27-2019, 01:23 PM
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Got an 09 xp 550 that takes a second, and more throttle before it engages and starts to move. It also clunks a bit when it finally engages. Belt? Clutch? Any ideas?
All the above plus drive line slack. You can change engagement rpm with different primary spring and/or weights.
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post #3 of 21 (permalink) Old 06-27-2019, 01:53 PM Thread Starter
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I just read that in the service manual, there is a red spring in there. Only problem is dont have a torque wrench that goes past 150 ft pds to put it back together.calls for 200 ft pds
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post #4 of 21 (permalink) Old 06-27-2019, 02:20 PM
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I just read that in the service manual, there is a red spring in there. Only problem is dont have a torque wrench that goes past 150 ft pds to put it back together.calls for 200 ft pds
You don't need any special tools or torque wrench to change the spring. You don't even have to remove the clutch from the machine. You simply get the clutch cover off and remove the six 10mm bolts (#12) that hold the outer cover of the clutch on. Pop the spring in and put the bolts back in. Doesn't take 5 minutes once the plastic clutch housing is removed.
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post #5 of 21 (permalink) Old 06-27-2019, 02:27 PM Thread Starter
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Okay I must have been misunderstanding something in the book I was thinking that the drive clutch retaining Bolt the one that has left-handed threads was the one that had to be torqued to 200 foot pounds. Okay so I could take the cover off and check the specs on the spring height to see if it's worn but I can't make heads or tails of this Spring chart in the service manual and what spring I should get to engage the clutch quicker they have a chart in the book that shows Force increasing in pounds between neutral and full up shift not really sure what that means.
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post #6 of 21 (permalink) Old 06-27-2019, 02:38 PM Thread Starter
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I took the pvt cover back off and look at the spring a little closer I have the red with black stripe which is second from Top I guess strongest spring? And I'm assuming I would need a weaker spring for It 2 engage quicker?
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post #7 of 21 (permalink) Old 06-27-2019, 02:39 PM Thread Starter
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Like I said there's eight other weaker Springs below the red one with the black stripe pick from and I don't have a clue which one to get
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post #8 of 21 (permalink) Old 06-27-2019, 02:50 PM Thread Starter
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Okay got the spring out the book calls for a free length of 2.82 in plus or minus 1/8 of an inch and it measures 2 7/8 so its within spec.
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post #9 of 21 (permalink) Old 06-27-2019, 06:37 PM
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How long have you owned this machine?
Did it use to have smooth take off engagement and now it don't? Or it never did?
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post #10 of 21 (permalink) Old 06-27-2019, 06:39 PM Thread Starter
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I really couldn't tell you I just noticed it. I inherited the ATV for my father who passed away last year and now I'm trying to get it In-Shape to sell it. I just did all the wheel bearings on it and moving it around here and there I noticed that it had that issue.
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