yes replace the springs. no lube on any part of Polaris clutches. only exception is the inner helix where it meets the steel shaft of the stationary sheave. the newer helix's have grease grooves for this. clutches need to be clean and rust free. every 400-500 miles blow the belt dust out of them. and after every season they should be removed and torn down cleaned and inspected. any worn parts replaced and new springs installed if you want peak performance.

 

If you want a little more pop out the sled you can buy a 7041080 blue primary spring. In the secondary run a slp black spring and use a 42/34 helix 2nd hole. Don't worry what you see for rpm on the stand. Run at least 96 studs in the track. On a good surface in winter temps you should see 8000-8150 running rpm. This what you want to shoot for.

 

Thanks. Yes there are grease grooves on the helix. Thats what was fairly gummed up. Had my son install 96 studs a few days ago ! Will that spring and helix setup you suggested be good for all around riding ? We mostly trail but will hit Castle Rock lake too. I have sunk a few bucks in this year so a few more wont kill me. Time for a new belt too. I just measured side clearance. Lets just say it was a little more than .20 ! More like an 1/8 inch. How about the old indy 500 Classic ? I may as well replace the springs on that too. Not even sure what that came with stcok.

 

Let him do the grunt work !

 

Yeah this clutch set up is pretty universal for all xlts. Our guys all ran it on the trails.

 

I guess I have a dinosaur. The helix is on back order from SLP and the black spring is no longer available !!!! So I guess I will just clean it up and put it back together with new polaris red spring. I think I may have to send the clutch in to shim since I dont have the tools necessary to take it apart. The 070 belt on it is only worn 1/32 but I have a belt to sheave clearance of about 1/16+ ! Anyone in north suburbs of Chicago able to shim my clutch ? I was thinking it may be set up for a wider belt but looking at belt sizes nothing really matches.

 

I have a belt to sheave clearance of about 1/16+

I got nearly the same clearance on my 97 XLT, looks like those primaries were setup with generous clearances...?

From what I hear, the 93-94 580 moters were prett good, 95-96/97 the troublesome years....?

And, if that 20 year old gold spring still engages at 4000, it has held up pretty good, I'd say
(unless its because of a sticky primary of course...)

 

Your most likely to need to have it re-balanced once its shimmed. Keeping a clutch properly balanced on any sled after any service as such should be done.

 

If I had the tools I would go for the .020 gap but a new belt should help. I did order a blue primary spring. Is it worth using it in place of the old gold since its on the way or should I just put it on the shelf if I cant get the helix and black spring? So far this 94 has been trouble free. I know that PTO side bearing was a weak point and mostly post 95. I cranked up the oil injection a bit to maybe give it a better chance of surviving.

 

My piped 93 lived around 9000 RPMs all day long! I have seen many piped early 580s Rock and Roll to 10000 miles. If you like the machine find a set of pipes, they are cheaper than the clutch kit used and will wake it up! Then you may need to clutch to get the RPMs in check. Other than warming it up before pinning it I would show it no mercy. I've held one on lean jetting over 1/2 mile and it lived. Have fun!

 

Pipes arent in the budget for this old dog ! I did find a black SLP spring so I ordered up the 40/34 helix and blue primary.

 

40/34 helix is ok but it will handle a helix that starts a little steeper. You got to careful how their cut. If a progressive type...not so good for trail riding.

 

Unless you prefer to ride like grandpa all the time leave the gold in there. The blue spring will make for a snappier takeoff. Its not crazy by any means. I can't stress enough about clutch balancing if you take it all apart for service. Trying to index it once re-shimmed imo never is good enough unless your real lucky. Especially should be done on an xlt motor.

 

Too Slow. i mis-typed. I am getting the SLP 42/34 ,black SLP spring and the blue poo primary. Sounds like that set up is tried and true ? I am going to get a new belt before I try and determine if it needs shimming. If it does I will get it done right. I hope this blue,black, 32/34 helix is a good combination for this XLT. I can always put the gold back in if it will play well with the black spring and helix. Neither my son or me will ever be riding like a grampa. Even though I am one !!!

 

I'm in joliet area and could help u re shim the primary if u want, then u could send it out and have it balanced.

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Really should run a blue spring with the components i mentioned. Yes its tied and works....just not as well with a gold primary spring.
...and its not that simple to get the correct amount of shimming and yet hit it within your index marks. Even if you get very close....still recommend to balance the clutch.

 

I have all the parts on order. Blue spring,SLP 42/34 and black SLP spring.I stopped at the closest Polaris dealer for chaincase oil and Polaris blue oil. They wanted 79 bucks for a belt. No thanks. I will order a belt and re-check clearance. If it doesnt need shimmed. I will leave it as is. Thanks for the offer 1fast...If I need to shim I may take you up on that offer.

 

$79.00 is a fair price for a poo belt. I don't recommend any aftermarket belt either if thinking that route. They throw the clutching off. Some are not the same compound or too far off on size that you have to drastically reset the deflection on your secondary.

 

Yeah let me know, I have all the stuff to reshim, and I work a lot cheaper than the dealer!

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Once. I take a home equity loan out to get a new belt on I will measure !:lol:

 

I thought Polaris belts were made by Dayco ???

 

All i can tell my past experience with belts directly made by dayco don't fit as well when replacing the poo belt and the compound is softer on a dayco belt....you end up with a little less run rpm. I found the wahl brothers belts pretty good...they are made by dayco or at least were.

 

Found all the clutch setup parts. Blue spring, 42/34 helix,black SLP spring. Have everything in hand and install tonight. Just in the nick of time. I am dragging the XLT back to the cabin this weekend. Thanks for the tips Too Slow and all. Hope we get some good snow in central Wisconsin this year. Son will be on the XLT and I will be on the Old Reliable 90 classic. Unless I find a super deal on something hi-po !