I read the thread on Kevcules and S10v84speed and am getting more familiar with this machine. Next time in there I will pry on the engine to see if it gets results due to mounts. The obvious thing to me right now is the surface of the sheeves on the drive clutch. From pics I`m seeing they are supposed to be flat where mine are grooved at the bottom. It accelerates and pulls smooth. It`s got over 6,000 miles on it. If this is absolutely unserviceable then maybe I should look at one for sale here on CL for $120. I am disgusted with this thing and haven`t bothered to mount the plow this year. Just been pulling trailer with wood from the field.

 

I`ve been reading my service manual and see the adjustment procedures. Also read that the sheeves shouldn`t show wear. Guess I`ll be looking into that drive clutch on CL. New one is $450. The clutch for sale is f rom a 300 explorer so is it worth changing over?

 

Had plenty of clutches that had some grooving along with small stress cracks,but still serviceable. Main thing is that the one way fiber and metal washer are replaced if needed,one way bearing is okay,clutches aligned. Yes worn/broken mounts can cause problems on creeping if that's your main problem.

 

Ok. Good to know. It doesn`t have EBS. Belt looked centered after I replaced it and was better at first. Now it`s worse than it was with old belt. Going to check center to center dimension and belt sag next. Just driving it around is ok but plowing is out with punishing the trans. If I ever get this fixed I`ll be very happy. I`m thinking it must be the engine sagging on the mounts making the drive clutch sheeves out of plumb? Thereby making the belt drag? What the heck is so different on the `02 model? The service manual mentions the belt sag being important and that makes some sense in that if I lift the bottomof the belt the driven stops turning. Allmost like if I put a piece of wood in there to keep the belt up that would fix it. Before I spend big bucks I`ll at least try it.

 

Always use low range under a load,will save the clutches and belts from stretching. If the belt sag is more than 1 1/2" it's sagged too far and needs to be replaced. There are 2-3 shims inside the rear clutch that can be removed to tighten the belt,but not if it's really worn. Place a straight edge over both clutches,pull down on the top part of the belt and measure this distance back to the straight edge. Plus use only OEM belts! Center of the drive clutch bolt to center of the rear clutch bolt should be exactly 10". If you're careful you can remove the belt cover and also check for clutch flexing while under a load. The left rear motor mount behind the clutch plate can separate/weaken along with the front mount also.Non ebs clutches shouldn't be that hard to work on. The 2002 Sportsman did have both non ebs and ebs systems. Plus recheck clutch for any button wear,sticking,etc along with the rear clutch ramp buttons if you haven't done so. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse