Join Date: Jul 2000
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Re: Polaris Clutch problems.
Go through and check the obvious spots first. Change the plugs if you haven't already done that. Change the plug wires too. A sled that age is due for a new set anyway. Remove the carbs and clean them thoroughly inside. Make sure the pilot jets are clean along with all the various small holes that you can see. It's possible that the ones that supply fuel in the transition between idle and full throttle are blocked with some debris or varnish.
As far as the clutch it may be something as simple as a broken primary spring. But pull both clutches anyway. Take the cover off the primary so you can pull the spring out. Wash the belt dust out with varsol. Check to make sure the weights pivot freely and the spider moves up and down without binding. It's quite likely that you will need to put some shims behind the spider buttons to get them in spec. You can pick up a shim kit from the dealer or get him to do it. The kit comes with instructions but you need to pull the spider in order to add the shims which requires some specialty tools.
Take the secondary apart by removing the snap ring on the back. When you take it out make sure you make note of which holes the ends of the spring are in. Check the helix ramp buttons for wear and replace if necessary. The parts you need are available from the dealer.