Polaris XLT Clutching Info?

dnale

dnale

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South Lyon, Michigan
I've been "deemed" to rebuilt my father-in-law's clutch on his 95 Polaris Indy XLT 600 tripple. We didn't have the puller at the cabin so I now am looking at getting parts and then going back up to do the install on the clutch. Does anyone have any info or what I should be looking for to install in here?
 
dont know the specific weight combo on this. but what to look for on the p-85 is worn buttons(you have to split the sheaves to change), bushings like to wear out in the cam arms as well as the pins and bolts. these parts are removable after the clutch cover comes off. check them closely as they are wear parts by polaris's own admission. as with any clutch, clean is good. wahl bros is a good source for the bolts, pins and bushings as the polaris dealer will not stock the bushings and try to sell you new arms. hope this helps.
 
Thanks snow. It would be a basic decent trail setup. He doesn't really ride the sled much. So something reliable that isn't a dog but doest need to be a rocket.
 
As someone else mentioned, worn weight bushings (if they're bushed) and bolts, rollers and pins, cover and inner sheave bushing - all for the primary. I used to oil the weights after every ride (made a bracket that would compress the sheaves which took pressure off the weights and allowed for working in Polaris Clutch Lube into the rollers and weight bushings).

I have all the needed tools for your o-haul but used up all the spare parts I had. PM me if you'd like to barrow them.
 
best tools are gas can and match...LOL

I was "voluntold" Id be helping my buddy with his exact same XLT, he traded it in and bought an IQ600....LOL

Good luck with this though, seems like you have the assitance of fellow members, as usual for this great site
 
The sled has actually been pretty good to him. He just put a new track on it two years ago and I don't think it was even run last year.

I recall him saying it would probably need new buttons and rollers.
 
I had an XLT that I put an EPI WHITE spring in the primary, made for a good trail rig, has a lower engagment for better trailability and had a YELLOW EPI spring in the secondary. I also had a second clutch set up with the BLACK EPI spring which has a higher engagement which made it launch great for an older sled. Used it for drags on the lakes. I know EPI also sells a rebuild kit for the polaris clutches.
 
Original 580 XLT with 34mm carbs- Aaen purple primary spring, 10MB weights, T-1 helix, and a Polaris blue secondary spring.

597 motors with 38mm carbs- Aaen purple primary spring, T-1 helix, Polaris silver/blue secondary spring, 10Ms weights ( 10MB weights in the 34mm carb sleds).
 
dnale said:
The sled has actually been pretty good to him. He just put a new track on it two years ago and I don't think it was even run last year.

I recall him saying it would probably need new buttons and rollers.
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We had a 96 XCR600 monobloc 597 until last fall. We installed an EPI clutch kit into it and we were very happy with it. All it ever needed was a clutch rebuild at like 4500 miles, gas, carbides, slides, and we studded it. It did need a new throttle cable in there as well, and a shock rebuild in like 2002 but for the 6500 miles it had on it, it was VERY reliable.

I bet even just new buttons and replaceable parts are all that are needed for that xlt.
 
horkn said:
I bet even just new buttons and replaceable parts are all that are needed for that xlt.
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That's what I'm looking for. Where's a good place to get these buttons and what are the other "replaceable" parts I should snag?
 
dnale said:
That's what I'm looking for. Where's a good place to get these buttons and what are the other "replaceable" parts I should snag?
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https://www.erlandsonperformance.co...n=CTGY&Store_Code=EPI&Category_Code=polclrbld

You may need to measure the rollers in there, apparently there were narrow and wide ones depending on year and model. EPI will probably be able to walk you through over the phone with what exact kit you need.

Personally, I would throw new springs on the primary and secondary while you are in there. So you might as well get a trail clutch kit.
 
dnale said:
That's what I'm looking for. Where's a good place to get these buttons and what are the other "replaceable" parts I should snag?
Click to expand...

I looked last night and still have enough parts for a primary o-haul minus the rollers and sheave/cover bushings. Primary buttons, shims, weights, bolts.

Nothing for the secondary except a few helix's.

I've yet to see a P85 of that vintage with any kind of mileage that didn't need a cover bushing. Won't feel much "seat of the pants" when they're worn, but it can bugger up the shaft of the fixed sheave if left unchecked for too long.

Over 12K on the original one on my old XCR and never needed an o-haul. That's not to say I didn't have it apart dialing it in, but with regular lubing of the rollers/weights/bolts/shaft, it was one of a few P85s I've worked on that didn't need a cover bushing or more.

I may be in Yipsi later this week visiting a friend that owns an Ammco trans shop on Hewitt. Let me know.
 
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