This is a relatively new atv to me. I have only ridden it 3 or 4 times and don’t know the full history. I had a belt grenade a few months ago and I’m finally getting around to replacing it. I believe the belt exploding was related to the fact that I have 14” rims and 27” Mudlite XTR’s, the stock clutch and I got stuck in snow in High(due to awd not working correctly). I will be installing a clutch kit as soon as I can. In the process I found the front motor mount was bad. I’ve replaced the front mount with the Napa replacement, but now it is nearly impossible to shift while the motor is running and creeps in gear.
I understand that those symptoms usually indicate clutches out of alignment, primary clutch bushing failure, one way bearing failure, belt tension issues or grooves on the primary clutch faces. I’m fairly sure the problem I’m encountering is the clutches are out of alignment. The belt is touching the outermost part of the primary clutch and has extra space on the other side (innermost part of clutch). The belt is the correct belt 3211130 that I purchased from the local dealership and the one way bearing feels like it spins smoothly and only one way, as it should. I’ve tried to adjust the alignment of the clutches with the front motor mount and that just seems to cause the belt to be cocked one way or another and causes the open space on the side of the belt to vary from place to place. I tried to remove the secondary (driven) clutch to try adjusting the number of shims but of course it’s stuck on the splines. I’ve ordered the secondary clutch remover, so hopefully will be able to try that soon.

My question is whether it’s normal to have to adjust the number of shims on the secondary clutch. It seems like once that has been done at the factory it shouldn’t have to be done again. That being said, the belt does seem to need to be moved towards the motor a little and removing one or 2 shims should accomplish that.

From what I’m able to tell the Napa front motor mount is slightly taller than stock, I haven’t been able to find anybody else having problems with the Napa mount, so I’m hoping that is unrelated to the issue I’m currently having.

 

Sounds to me like you need the clutch alinement tool. There are some for sale on ebay.

 

I’m not against buying the clutch alignment tool, but I believe moving the secondary clutch towards the transmission slightly should resolve the alignment issue. I’m just not sure how that could be necessary.

 

this is the stock belt for the 05' 800
3211106Belt, Drive
not sure if your number is correct or not as the polaris site doesn't show anything w/ that number. i'm they may have replaced the stock pn# w/ another belt by now. usually you only move the shims if the belt is worn some. you really shouldn't have to move them to make the belt work. maybe the engine is out of alignment.

 

Normally you shouldnt have to adjust the alignment unless the machine has been taken apart. I would doubnle check all the motor and tranny mounts to make sure they are good. If everything is put together correctly and its still out of alignment the only real options you have is try adjusting motor and/or the tranny Or to add/remove the shims behind the secondary.

Any chance that the idle has been turned up. If it is to high it can idle at the engagement rpms and cause the shift issues.

 

The belt 3211106 was replaced by 3211130. I don’t doubt the engine is possibly out of alignment. I tried to put the new mount in while keeping the bolts in the exact same place as the previous mount had been in but that didn’t work out. The new mount is slightly taller so that could play into the issue. I tried moving the engine around while it was running to see if could get things lined up but no matter where I put the engine it wasn’t working out. It seems like you can tell when the belt is out of alignment by the way it acts. When you have it wrong there is a lot of bouncing and fast vibration visible on the belt. Where its sitting now it appears straight, just touching the outermost part of the clutch. Its tight enough of that you cant get your fingernail in between the clutch wall and the belt all the way around the one way bearing (on the outermost part of the clutch). The gap on the other side of the belt, while bigger than it should be, seems to be equal all the way around the one way bearing.



The idle is at 1200. I dont think that is the problem. Its obvious the belt is riding up against the clutch on one side.

 

I would try taking a washer out from behind the secondary then. Sometimes you might need to find a thinner washer to fine tune it.

 

By washer do you mean shim? If that's the case, i plan on trying that as soon as i get the secondary puller i ordered.

 

Most of the time you don't need a puller for the rear clutch.

 

Also sometimes you can get a bad belt and it causes this.