Hi All,

First off I am glad I was able to find a ATV Forum site that I could actually access from an Army internet connection. The Sportsman 400 I use is messed up. The belt is slipping, but not really.. So after reading through a bunch of old posts I come to realize that the problem was most likely my Secondary clutch buttons. So I took the secondary clutch off and sure enough they was a "rattling" sound, which was likely the broken buttons. After taking about the clutch, I verified the buttons were toast. The Helix was fine though - no metal to metal wear which is good. So I ordered new buttons from Bikebandit.

My question is this:

When re-assembling the Secondary clutch do you need to rotate the Helix 1 full rotation before "Keying" it to the inner shaft? The reason I ask is that I re-assembled it (just so everything stays together). Well I only has to rotate the Helix 1/5th of a rotation before it keyed onto the inner shaft.

Thanks

 

If its like the SP500 clutch, no. Just put your spring in the holes that you want, I used 2/2, and put it back together.

 

Ok, well when I took it apart is seemed like the Helix released more tension than I applied when putting it back together....

 

This is the easiest way we have found to describe this in our clutch kit instructions.

Once the spring is in place, push the helix down 1/2 - 3/4 of an inch until it engauges the splines. Then rotate the movable sheave counterclockwise 1/3 of a turn and hold it. Now push the helix all the way down on the spline and reinstall the snap ring.

So yes there is a littel bit of side tension on the sprig as well. I sure hope this helps If you have any more ?'s please feel free to ask.

 

Ok, cool - thanks for the tips! My order just shipped from Bike Bandit today... so by the time my Mom gets it and then sends it to me over here in IRAQ.. it will still be another 2 weeks... so I will let you know how I make out...

Also, I believe there are 3 Positions on the Helix and 2 internal to the sheave (or vice versa) There are set at 2/2. What are the advantages of changing the Setting on these? We mostly use the Quad to get around the base... but occasionally.. ok about once a week... I take it out and go 4 Wheeling (Smiling) it is a good reality break from the day in / day out rigamo of the War...