I have a 2003 Sportsman 500 H.O. with about 800 miles. I purchased it a year ago, sent it in for a dealer to go thru, they changed all fluids and replaced the belt. This summer I had a problem with the clutch slipping, it would crawl, and I had problems getting it in gear. I took it to the dealer, and they again replaced the belt. The latest is running this weekend (tough conditions, heavy snow) the belt shredded into pieces, I didn't even know what it was until I say pieces of the belt . The bike won't start and you cannot even pull the cord out on the pull start, I assume the rest of the belt is tied up inside. I have yet pull it apart. I love the machine but am losing faith in the dealer. Any idea of what the problem might be. Trying to get a little information before I again take it into for service.

 

if the bike was creeping ahead and it went though a belt, chances are the ebs bushing inthe primary clutch is bad and froze up. take off the clutch cover and take a look at whats going on and if the belt is all messed up clear the debri and then make sure the engine freely turns over. also make sure the engine isnt loose on the engine mounts. get back to us after you have done this and we'll tell you what to look for next on the clutch.

 

Thanks for the quick response. I take apart and get back to you, won't be before next weekend. Bike is at camp and didn't have time to pull it apart before I left. Life would be great if we didn't have to put our toys away and go back to work each week!

 

Who said I put my toys away? I'm retired (not tired).

 

Rub it in Mongrol, rub it in. [img]i/expressions/face-icon-small-wink.gif[/img]

 

yea i dont think theres to many independtly wheathy people on asking for advice on how to fix there own bike. so we have to work lol[img]i/expressions/face-icon-small-happy.gif[/img]

 

Duser, this may not have happen to you, a friend was ridding his 500. Tried to take off from a dead start up a small but very steep hill in high range. Smoked his belt, later that day after miles of ridding the belt shredded. Once the belt let's the smoke out, it want last long.

 

<div class="FTQUOTE"><begin quote>Originally posted by: hc

Duser, this may not have happen to you, a friend was ridding his 500. Tried to take off from a dead start up a small but very steep hill in high range. Smoked his belt, later that day after miles of ridding the belt shredded. Once the belt let's the smoke out, it want last long.</end quote></div>

Thats what happens 99% of the time when someone has belt troubles! If it doesn't move with very little throttle get in low range! I burnt a couple belts on my Scrambler this way, should've stayed out of the nasty stuff. Now with the Scrambler I just hit the hills like a sort bike WOT!
I just wish there was a way to have high/low shift on the fly!

 

I'm sure I smoked the belt because of the conditions and I was in high range. Still wonder why the third belt, the others must have been getting worn, they were just replaced before I blew them. My bike did run after the puff of smoke as well, then ripped apart. A friend of mine I was riding with suggested it was because I was in high range, I didn't want to agree with him, but I guess i am going to have to listen to him tell me how he was right everytime I go riding with him. I have never replaced the belt, I would think it is something I could do myself, or at least I should learn how.

 

Polaris belt change video.

Its simple.