Broken Primary Springs

[10003514]

2023 Khaos Boost 155. I have 610km on the sled and I’m on primary spring number 4. Seem to last 1-1.5 rides and breaks in pretty much the middle of the spring. I bought glide washers from Fire and Ice after breaking 2 springs. My last ride I thought I had the problem solved but broke a spring again today with roughly 120km on it. Any other recommendations? Aftermarket springs any stronger. I don’t want to keep buying a $90 spring every ride.

 

[Sheetmetalfab]

2023 Khaos Boost 155. I have 610km on the sled and I’m on primary spring number 4. Seem to last 1-1.5 rides and breaks in pretty much the middle of the spring. I bought glide washes from Fire and Ice after breaking 2 springs. My last ride I thought I had the problem solved but broke a spring again today with roughly 120km on it. Any other recommendations? Aftermarket springs and stronger. I don’t want to keep buying a $90 spring every ride.

Warranty will replace them.

A warranty history of 4 broken springs would get you a new clutch. (If you had the history)

 

[kanedog]

What spring part num are you using?

 

[10003514]

Warranty will replace them.

A warranty history of 4 broken springs would get you a new clutch. (If you had the history)

Good to know. I’ll have a chat with my dealer.

 

[10003514]

What spring part num are you using?

7045965 Spring Clutch Drive 165/310 is what the local dealer has been giving me.

 

[Popik]

Are you running stock weights ?
this seems odd.

 

[SHERMAN]

Could it be a clutch balance issue? Breaking from excessive vibration? If it’s not coil bind or physically burring into the clutch some where.

 

[JH@CM]

Yah, after so many springs I'd be asking for a new primary... or if they balk, can you send the primary somewhere to be balanced?

 

[10003514]

Are you running stock weights ?
this seems odd.

Yeah 100% stock clutch, only added glide washers.

 

[tmberro]

I was going through a spring a ride on my 9R. I switched to a venom spring and I am 4 rides into the spring now. Venom has the stock boost spring rate available (orange). Might be worth a try.

 

[die hard poo]

Ya I would try an SLP or a Venom spring because they aren't beehive shaped where they get fatter in the middle like the stock spring. The most likely problem is that the spring is rubbing against the spider and causing it to break. The SLP or other springs are straight and will give you some clearance in the spider. Mine so far have lasted around 500 miles on my 9R. Plus theyre only like $30 vs the stock one...

 

[10003514]

Just ordered 2 Venom springs, hopefully that solves my issue as I’m riding in the next few days, started a warranty history with me dealer about the broken springs will see where that ends up.

 

[carbontj]

adding glide washers wont help as the real issue is there is not enough room for the heavier spring that is needed for the Boost..There are almost maxed out for stiffness of spring. All one can do is grind the sharp ends so it wont grab the spider or cover as hard...issue is it is coil bound...Has to be a bitch to change a spring in the field with the red loctite on the cover bolts...need a impact almost...and hard to compress the spring and start the bolts/bolt...

 

[10003514]

Is that not the purpose of the glide washers to avoid coil binding ? Gives the steel spring a hard surface instead of the aluminum spider and cover so I don’t have to grind the spring ends.

 

[Sheetmetalfab]

Is that not the purpose of the glide washers to avoid coil binding ? Gives the steel spring a hard surface instead of the aluminum spider and cover so I don’t have to grind the spring ends.

Glide washers have some thickness and make the spring more coil bound. (Less room)

 

[sledder51]

adding glide washers wont help as the real issue is there is not enough room for the heavier spring that is needed for the Boost..There are almost maxed out for stiffness of spring. All one can do is grind the sharp ends so it wont grab the spider or cover as hard...issue is it is coil bound...Has to be a bitch to change a spring in the field with the red loctite on the cover bolts...need a impact almost...and hard to compress the spring and start the bolts/bolt...

I carry an extra bolt (approx 10mm longer) to get them started, then once the rest are started, I remove it and replace it with the original.

 

[AdrenalineAddict]

This seems to be a common problem this year with Polaris riders I ride with, I broke a few myself over the last couple seasons and have been on several rides this year where somebody in the group has a broken spring. I went directly to venom and my problem went away??

 

[Jaynelson]

The most likely problem is that the spring is rubbing against the spider and causing it to break.

Have definitely seen this on 9R and boost this year

 

[LPIdaho]

Stock springs are too long. Need to switch to Bikeman or Speedwerx to get rid of the coilbind.

 

[JH@CM]

Has anyone measured some new stock vs. aftermarket springs for length and diameter?

With so many breaking, I wonder if it's a manufacturing or oem spring specification problem?