I am looking for info on the engagement and peak RPMs for my 1991 cougar 440. It does not have a power valve nor reeds(Piston contolled intake). If you don't have the numbers for that exact sled, something close would be fine. I am currently operating with a new clutch and the RPM seem a little high. It is engaging at 5000RPM with a peak at 8000RPM. Just need to know if I should invest in some heavier cam arm or not.

Its been 15 years since i rode a 91.. lol.. first year liquid for cougar.. imo, 5000 seems pretty high for engagement on this sled,, thats later ZR 440 territory,, not as sure about peak... if u don't have the owners manuel, can u poss. call a dealer and ask?? I had older 86 cougar,, and i know that sled engaged at like 3600 max.. and full peak was at 7200 rpms or so.....

If 5000 is too high for your riding stlye,
, the last 440 I rode engaged at 4600, the dealer should be able to tell you.
A new spring is all you should need.

x2 on the spring! 5k is WAY too high. It should be closer to 3500.

I thought that it was to high for this vintage. I put a new clutch from an unknown sled on. Probably from a newer sled(Ebay $50.00 Comet EXP) The original clutch was in real bad shape, one of the weights broke off. I will try the spring from my original clutch. It does pull really nice though, just don't want to spin a bearing or throw a rod. I'll also try the local a/c dealer.

I'd stay away from "unknown" clutches... if you get the wrong clutch in there you can do some serious damage to your sled! That's how my zrt went... previous owner had a polaris clutch in it and it blew apart and wrecked everything.

If the basic clutch you have fits your machine properly, you can probably put the correct weights and original (or OEM setup) spring in it and you'll be good. I'd expect 35-40 and 70-72 - all x 100- on respective rpms.

I finally figured out what I have with my new clutch

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Engagement 5000RPM

Max RPM 8000

Polaris Blue Spring 130/300

Cam Arm 10MW 46Grams

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I looked up the stock spring for this sled and it is:

Blue/Red 68/197

Cam Arm 47G



I figured the Cam arms are close enough



How much would the engangement RPMS drop if I went to the stock spring, droping the engagement force by 77lbs. I do understand the max RPM is almost impossible to estimate, so I won't even ask. but the engagment is a function of RPM only, so I would guess someone should have an idea.