I decided to replace my primary spring in the scrambler 500 with a Polaris white spring. (was a smaller blue one) Put it in lastnight and took it for a spin. What Im looking for is low end grunt. Basically when I hammer the throttle (even with my 250lb *** on the back) the thing wont pull up with out some major yanking. Now Im coming from the sport world (Honda and Suzuki) so Im wondering if Im being unrealistic with my expectations? Have heard I can adjust my secondary clutch setting. Can someone tell me exactly how/where this is and what to do? I was messing with the clutch lastnight and took the second wheel (clutch? tensioner?) off to inspect the belt. The belt looked new and had roughly 1 1/2" of play pushing straight down in the center. The clutches dont smell burnt while accelerating or straining. Dont get me wrong it moves, but it seems to wake up in the mid range. Its all stock besides the spring. I was wondering if a k&n with the airbox mod would help? would like changing the secondary to the (2?) setting help? Assuming it isnt yet. The power is there, just not where I want it.

 

Here is the Aaen stage 5 kit.



Here is there link,might be worth a look.http://www.aaenperformance.com/Power500.asp. Seems blue/ red is there choice of springs.

 

You probably won't be able to see much of a difference in playing around with the primary and secondary clutch springs on a stock machine.The biggest difference's that you will probably notice are going to be your stall speed and maybe a little more top end.

I'm not that familar with the Polaris 4 strokes, but you might want to post your question over on the GEN3USA site in the 500 forum.Most of those guys know their stuff when it comes to setting up the clutching and moding the Scrambler 500's.Aeen is also a good place to talk with for mods as well as Rick Ritter at RCR.The motor in my Sport has been built by Rick at RCR and Aeen has helped me setup my clutching and carb.

 

Set the secondary at 2-2 and try that.Do a search on here on secondary clutches.
Old Polaris Tech posted the best instrutions I have seen on that.

 

The white spring I put in was at least 1 1/2" taller than the blue one I removed. This sound right? When I removed the primary spring cover (held in place with 6 bolts) I didnt mark it. Im sure it went back on in the same position. Is there anything else I should have been looking for? When I removed the main bolt holding the cover and spring in position a little black spacer/wheel came out. Im not positive I put that back in correctly. Does that go in the center shaft on the outside of the spring or was it suppose to be behind the spring? I tried to slide it through the shaft but it wouldnt make it through the threaded shaft. Its currently installed right behind the center bolt head on the outside of the spring.

 

sorry dont mean to jump in and change your guys conversation here just need some help getting my primary off... you guys seem to know a thing or two about the clutch, tricks or tips i need here? thanks

 

Put it back together and use a clutch puller

 

So is the spring height difference normal? Also any ideas if the spacer is in the right location?

 

The height is ok.Just gives more engagement rpm