Polaris General Clutch Problems

The Polaris General, known for its versatility and blend of work and play capabilities, is a popular choice in the UTV world. However, like any machine pushed to its limits, it's not immune to problems. One common area of concern for General owners revolves around the clutch. A malfunctioning clutch can turn a fun weekend adventure into a frustrating mechanical nightmare, impacting performance, fuel economy, and even causing further damage if left unaddressed. Let's dive into the common clutch issues plaguing Polaris Generals and what you can do to get back on the trail.

Understanding Your Polaris General's Clutch System

Before we tackle the problems, let's briefly cover the basics. The Polaris General uses a Continuously Variable Transmission (CVT) system. Unlike a traditional manual or automatic transmission with fixed gears, a CVT uses belts and pulleys to provide a seamless range of gear ratios. The heart of this system is the primary (drive) clutch and the secondary (driven) clutch.

• Primary Clutch (Drive Clutch): This clutch is connected to the engine. As the engine RPMs increase, centrifugal force causes the weights inside the primary clutch to move outwards, squeezing the belt and engaging it.
• Secondary Clutch (Driven Clutch): This clutch is connected to the transmission. It reacts to the belt tension and engine load, shifting to provide the optimal gear ratio.

The belt is the crucial link between these two clutches. When everything is working correctly, this system provides smooth acceleration and efficient power transfer. However, when things go wrong, you'll definitely notice.

Common Clutch Problems: The Culprits Behind the Issues

Now, let's get to the meat of the matter: the problems that plague Polaris General clutches.

1. Belt Slippage: The Most Frequent Offender

Belt slippage is arguably the most common clutch-related issue in Polaris Generals. It happens when the belt fails to grip the clutch sheaves (the pulley surfaces) properly.

• Symptoms: Squealing or chirping noise, especially during acceleration; sluggish acceleration; loss of power; burning smell.
• Causes:
  • Worn Belt: Over time, the belt wears down, losing its grip. This is especially true if you frequently engage in high-load activities like towing or climbing steep hills.
  • Contaminated Belt or Sheaves: Oil, grease, mud, or even excessive dust can contaminate the belt and sheaves, reducing friction.
  • Incorrect Belt Tension: Improper belt tension, often caused by worn or damaged clutch components, can lead to slippage.
  • Overheating: Excessive heat can glaze the belt, making it slippery.
• Solutions:
  • Inspect the Belt: Look for cracks, fraying, glazing, or excessive wear. Replace the belt if necessary. A good quality aftermarket belt can often outperform the OEM belt.
  • Clean the Belt and Sheaves: Use a dedicated clutch cleaner or isopropyl alcohol to clean the belt and sheaves. Avoid using harsh chemicals or solvents that can damage the rubber.
  • Adjust Belt Tension (If Applicable): Some models have adjustable secondary clutches. Consult your owner's manual for the correct procedure.
  • Consider a Clutch Kit: If slippage persists, a clutch kit tailored to your riding style and terrain may be necessary.

2. Clutch Engagement Issues: Stalling or Jerky Starts

Sometimes, the clutch might not engage smoothly or at the correct RPM. This can lead to stalling, jerky starts, or difficulty engaging gears.

• Symptoms: Stalling at low RPM; jerky or abrupt engagement; difficulty shifting into gear; inconsistent acceleration.
• Causes:
  • Worn or Damaged Clutch Weights: The weights inside the primary clutch are responsible for engaging the belt. If they are worn, damaged, or improperly weighted, the clutch may not engage smoothly.
  • Sticking or Binding Clutch Components: Dirt, debris, or corrosion can cause the clutch weights, rollers, or buttons to stick or bind, hindering smooth engagement.
  • Weak or Broken Clutch Springs: The springs in the primary and secondary clutches control the engagement and shift characteristics. Weak or broken springs can lead to erratic engagement.
• Solutions:
  • Inspect Clutch Weights, Rollers, and Buttons: Check for wear, damage, or excessive play. Replace worn or damaged components.
  • Clean and Lubricate Clutch Components: Disassemble the clutches and clean all components thoroughly. Use a high-quality, dry-film lubricant specifically designed for CVT clutches. Avoid using grease, as it can attract dirt and debris.
  • Replace Clutch Springs: If the springs are weak or broken, replace them with new ones. Consider upgrading to stiffer springs for improved performance, especially if you frequently ride in challenging terrain.

3. Clutch Noise: Squealing, Rattling, or Clunking

Unusual noises coming from the clutch area are often a sign of underlying problems.

• Symptoms: Squealing, chirping, rattling, clunking, or grinding noises coming from the clutch area.
• Causes:
  • Worn Belt: As mentioned earlier, a worn belt can cause squealing or chirping noises.
  • Worn or Damaged Clutch Bearings: The clutches contain bearings that allow them to rotate smoothly. Worn or damaged bearings can cause rattling or grinding noises.
  • Loose or Broken Clutch Components: Loose bolts, broken springs, or damaged weights can cause rattling or clunking noises.
  • Misalignment: Misalignment between the engine and transmission can put excessive stress on the clutch system, leading to noise and premature wear.
• Solutions:
  • Inspect the Belt: Replace the belt if it is worn or damaged.
  • Inspect Clutch Bearings: Check the bearings for play or roughness. Replace them if necessary.
  • Tighten Loose Bolts: Check all bolts in the clutch area and tighten them to the correct torque specification.
  • Inspect for Broken Components: Look for broken springs, weights, or other components. Replace them as needed.
  • Check Alignment: Ensure that the engine and transmission are properly aligned.

4. Overheating: A Silent Killer

Excessive heat is a major enemy of CVT clutches. It can damage the belt, glaze the sheaves, and shorten the lifespan of all clutch components.

• Symptoms: Loss of power, especially during sustained high-speed driving or hill climbing; burning smell; belt slippage; premature belt failure.
• Causes:
  • High Load Conditions: Towing heavy loads, climbing steep hills, or driving in deep sand or mud can put excessive strain on the clutch system, generating a lot of heat.
  • Low Gear Driving at High Speeds: Driving in low gear at high speeds can cause the engine RPMs to be excessively high, leading to overheating.
  • Inadequate Clutch Cooling: Some Polaris Generals have limited clutch cooling.
  • Improper Clutch Calibration: Incorrect clutch calibration can cause the belt to slip, generating excessive heat.
• Solutions:
  • Reduce Load: Avoid towing excessively heavy loads or climbing extremely steep hills.
  • Use the Correct Gear: Use low gear only when necessary. Avoid driving in low gear at high speeds.
  • Improve Clutch Cooling: Consider installing a clutch cooling kit or vent to improve airflow around the clutches. Many aftermarket options are available.
  • Re-Calibrate the Clutch: If you frequently ride in challenging terrain, consider re-calibrating the clutch with a clutch kit tailored to your riding style.

5. One-Way Bearing Failure

Some Polaris General models have a one-way bearing in the primary clutch. This bearing allows the engine to freewheel when decelerating, providing smoother engine braking.

• Symptoms: Engine braking that is too abrupt or jerky; difficulty shifting into gear; unusual noises from the clutch area.
• Causes:
  • Wear and Tear: Over time, the one-way bearing can wear out and fail.
  • Contamination: Dirt, debris, or water can contaminate the bearing, causing it to bind or fail.
• Solutions:
  • Replace the One-Way Bearing: If the one-way bearing is worn or damaged, it needs to be replaced.

Preventing Clutch Problems: Proactive Maintenance is Key

The best way to avoid clutch problems is to practice proactive maintenance.

• Regularly Inspect the Belt: Check the belt for wear, cracks, fraying, or glazing. Replace the belt as needed, typically every 1000-2000 miles, or more frequently if you ride in challenging conditions.
• Clean the Clutch Components: Regularly clean the belt and sheaves with a dedicated clutch cleaner.
• Keep the Clutch Housing Clean: Remove any dirt, debris, or water from the clutch housing.
• Use the Correct Gear: Use the correct gear for the terrain and load. Avoid driving in low gear at high speeds.
• Allow the Clutch to Cool Down: After sustained high-speed driving or hill climbing, allow the clutch to cool down before continuing.
• Consider a Clutch Kit: If you frequently ride in challenging terrain, consider installing a clutch kit tailored to your riding style.
• Follow the Manufacturer's Recommendations: Follow the manufacturer's recommendations for clutch maintenance and service.

Frequently Asked Questions

• How often should I replace my Polaris General's clutch belt? It depends on your riding style and conditions, but generally every 1000-2000 miles. Inspect it regularly for wear.
• What is the best way to clean my clutch sheaves? Use a dedicated clutch cleaner or isopropyl alcohol. Avoid harsh chemicals that can damage the rubber.
• What is a clutch kit, and do I need one? A clutch kit replaces springs and weights to optimize performance for your riding style. It's beneficial for those who frequently tow, climb, or ride in mud.
• Why is my clutch squealing? A squealing clutch is usually a sign of a slipping belt. Inspect the belt for wear and clean the sheaves.
• Can I use grease on my clutch components? No, never use grease on clutch components. Use a dry-film lubricant designed for CVT clutches.

Conclusion

Polaris General clutch problems are a common headache, but understanding the underlying causes and practicing proactive maintenance can significantly reduce your chances of encountering them. By regularly inspecting your belt, keeping your clutch components clean, and riding responsibly, you can ensure that your General's clutch system stays in top shape, allowing you to enjoy worry-free adventures for years to come.