I have a 1994 sportsman 400 and am having a problem with the belt slipping. I was using it in low range to pull a garden tiller behind it and it was a really hot day and the clutch got real hot and started melting the plastic cover. Then I could barely get the machine to move so I was hoping I just cooked the belt because the sides of it were very hard and looked burnt but I got a new belt and it still won't work. With the new belt it works fine when driving slow with little throttle but when I give it throttle to accelerate the belt slips and grinds. When I took the old belt off I started it up and reved the motor and the clutch moved in and out like it should. I wasn't putting much strain on the quad exept for stop and go and driving at a crawling speed. Any ideas on what the problem could be? The quad has 2100 miles on it and most are easy miles.

 

Marko:

Do a search for " No shifting ! " alot of good explainations and things to check in that thread.

...Honcho

 

Try checking the secondary clutch .See if when you turn the halve in opposite directions if they snap back.This clutch could have either abaad spring or bad byttons.

 

Thanks, I will check that. Any other ideas?

 

Anyone ever have a similar problem. I am still looking for ideas.

 

Try inspecting the rest of the drive line for worn or binding parts. Also, Make sure the sheave's are clean, any oil or other contaminate's can cause belt slipage. If it got that hot, I might consider replacing the springs also, they may have lost some of their "spring" if they were exposed to excessive heat for an extended period.

 

Everything seems to look ok. When I changed the belt I took the old belt off and pushed on the clutch and it moved in and out like it should. I also started it up and revved the motor and the clutch seems to work fine. I used a scouring pad and rubbed the sheaves to make sure to get all the residue off. The belt slips real bad when I hit the throttle though. Do you think one of those rebuild kits for like 120 dollars will fix it?

 

Check the secondary like ftwflh suggested first. Rotate the pulley half to see if it snaps back. Is the belt to the outside of the secondary pulley or is it down in the center when you hit the throttle? Is the parking break on? If you lift the bike on stands do all the parts rotate freely? How old is the belt?

 

Check for binding on the driveline, lift the back wheels off the ground and turning the secondary clutch in gear you should easily be able to turn the back wheels. If not check the dirve train, brakes etc.