Ok I shredded half my drve belt saturday. Just put on the replacement, I let it idle for a min or so then gave it a few cycles up and down. I am sort of suspicious that at high speed the primary and secondary aren't 100 percent aligned. It seems like it is rubbing the inside of the sheave a little.
It doesn't ride up or anything. My questions are
1. how can I diagnose/fix this?
2.What I may be seeing an optical illuson, it is hard to tell looking down with both sides moving opposite. If it is misaligned it is very slight at near top engine speed. is this a problem to just run it this way? will I damage something permanant? It only happens at very high rpm.
3.It's a 2002 sportsman 700 And the motor mounts are good. Any other ideas what may have caused this?


Thanks everyone!!

This message has been edited. Last edited by: hughjazz,

You just diagnosed it, now you need to add or remove a shim under the secondary or loosen and move the engine on the mounts. Polaris has a tool for this, I just moved mine till it was centered.

yeah, u can view from the top and see if it is riding on one sheave or the other, and if it creeps it definitely needs to be aligned

to adjust, add or remove shims behind the secondary clutch

quote:

Originally posted by RickCJ7:
You just diagnosed it, now you need to add or remove a shim under the secondary or loosen and move the engine on the mounts. Polaris has a tool for this, I just moved mine till it was centered.

Alright I haven't really looked at my manual yet but Is removing the secondary as easy as loosening the bolt and pulling it off? Then remove a shim? (belt rides towards the engine on the primary side) Then putting it back? thanks

Just to clarify after reading the previous posts.
-the bike doesn't creep at all.
-the belt stays centered in the sheaves, the belt just seems to deflect sideways like 1/16" at high speed only. If it was an alternator or power steering belt it would be left alone for sure! I Just don't want to cause permanant damage. Also if I remove a shim,, what has happened to make the clutches mis alligned? thanks again.!!

How many miles do you have on it. There's a chance the clutches need to be rebuilt. Parts will wear out over time. The clutch bushings can wear and loosen things up in terms of movement and can cause alignment issues. I'd remove the belt and cycle the primary clutch and check for unwanted movement.

hey cajun are you saying run the engine with the belt off and check for movement ???

quote:

Originally posted by Cajun:
How many miles do you have on it. There's a chance the clutches need to be rebuilt. Parts will wear out over time. The clutch bushings can wear and loosen things up in terms of movement and can cause alignment issues. I'd remove the belt and cycle the primary clutch and check for unwanted movement.

The bike has around 1030 miles. I did run it before I put on the belt, It all seemed smooth and quiet. not really sure what you mean by unwanted movement. The primary seems (from my observation) to be working well.

On a side note.
does anyone else think that the factory polaris manual is a little short on pictures and details? jeez I read the whole section on the drive system last night and it seems as clear as mud.

Also cajun What does the heel clicker kit include? Springs and weights? I was wanting to purchase one. I thought that when I was setting the clutch up I would learn how it actually goes together. Do you sell them or just cob? he is hard to get a hold of.

thanks

That would be Cob. I don't have any association with Heelclicker. I just pass on info I develop from my testing as well as the results of others that post here.

The movable sheave rides on the fixed sheave via a brass bushing. Same goes for the face plate. The bushing can wear out over time and make the moveable sheave loose on the shaft. These movements can wreak havoc on belt alignment. Of course there are other parts that wear, weights, rollers, not to mention the secondary.

quote:

Originally posted by hughjazz:

quote:

Originally posted by RickCJ7:
You just diagnosed it, now you need to add or remove a shim under the secondary or loosen and move the engine on the mounts. Polaris has a tool for this, I just moved mine till it was centered.

Alright I haven't really looked at my manual yet but Is removing the secondary as easy as loosening the bolt and pulling it off? Then remove a shim? (belt rides towards the engine on the primary side) Then putting it back? thanks

Yes just remove bolt and slide secondary off should be 2-3 shims, sounds like you need to add 1 to get the secondary out to match the primary. If its centered at idle and doesn't creep, I'd let it alone. Why did the belt go? did you slip it in high range? The twins have enough power to slip the belt if you try to start out on a steep hill. I ride lots of mountains and you need to use low to get moving on most of them. Or get on it and get the wheels moving quickly. Don't pull out easy and slip the belt.
Just to clarify after reading the previous posts.
-the bike doesn't creep at all.
-the belt stays centered in the sheaves, the belt just seems to deflect sideways like 1/16" at high speed only. If it was an alternator or power steering belt it would be left alone for sure! I Just don't want to cause permanant damage. Also if I remove a shim,, what has happened to make the clutches mis alligned? thanks again.!!

well I bought it used,,, 150 miles ago. The previous owner said he had replaced the belt once before. I know he did a lot of sand running.

Anyway I was doing very long steep hills for 2-3 hours usually at light throttle. I did start and stop on the hills several times. And I was in high range. Being as how the motor didn't seem to bog down it seemed like the right range to be in.


I am learning that the cvt is a diffrent animal than 4x4 trucks. I have a built in tendancy not to mash the gas too hard because in my trucks I don't want to slip the clutch. Seems like the cvt likes to get on it quick though.

I think what I am going to do is leave the new belt on and see how long it lasts. (hoping my last belt broke because of operator error; rather than the clutch.)



I bought a dayco belt for $50 I plan to use for the next 100 miles or so. If it holds up that long I will buy the polaris belt $90 and use the dayco as a spare. Btw do you all carry a spare belt?

Thanks again everyone. Nothing better than practical experience to give a guy some help

Look at the sheave faces pretty closely and make sure there are no visible cracks. That's a good indicator that the clutch has been abused and not long for this world.