I just bought the EPI pro clutch kit and installed it with a new belt. What a difference. It will now power wheelie in high with no help from me. No more cherping of belt when under load but does whistle a little when idling in gear. The stock belt had almost 2" of play before I took one shim out. I want to thank everyone for the good advice! GreenGoblin2 thanks for the web sit for changing the clutch springs and shims, it was very easy with those instructions.

04 650 AC
EPI Red Secondary
EPI Pink Primary
High Lifter 2" lift kit
High Lifter CDI Module
28" ITP mude lites
2500# Winch with pully block

 

I hope everyone is using this machine in low range most of the time. It would end alot of your belt problems if you are'nt

 

Mine reaches 50 mph in low range. There's a dirt road at our riding club that's called the "Turnpike". It's about 4 miles long, really wide, and mostly flat. Only time I use high range is riding to turnpike to see how fast I can go. Got up to 68 mph last week [img]i/expressions/face-icon-small-happy.gif[/img]

 

You would be surprised how many customers come back with belt problems just for that reason. I explain to them when they buy the machine to run it in low range most of the time and why. Once they see how much it cost to get a belt changed they go to low range real quick.

 

Swampeater - Nice to hear everything worked out for you.

What EPI pro clutch kit did you get? I didn't do the weights, all I did was the primary and secondary, I'm woundering if I should of done the kit. I also noticed that you have the red secondary, is the engagement hard and noticeable?

arcticmech - I ride in low under 25mph, in deep snow and thick mud. These mods and adjustments fall into the category of fine tunning, not necessarily belt problems.

 

This is the kit I put on :
Pro-Series Clutch Kits
Kit includes primary spring, secondary spring and 1 set of EPI "Belly Buster" weights.
Designed for the most aggressive acceleration possible.
Enhances backshifting and throttle response.
Improves holeshot.
Allow clutches to squeeze the belt better to minimize belt slippage.
Models With Ignition Module Year Part # 650 4x4 - Oversized Tires 04-05 WE490685 Kit cost $199.00

I can only compare it to stock and it is %1000 better. In super thick mud It would cherp and bog in reverse and now it will hook up and throw you to the handle bars. It starts out about 200 to 400 rpm higher than stock and if you are gentle on throttle it starts moving pretty smooth but if you thrash the throttle it hits hard and gets you going. The front end will go straight in the air in high or low from a dead stop on hard ground.

The biggest difference I notice is when riding slow in thick mud and trying to get over logs while in mud, The motor would bog down and belt start to cherp, and now it has zero slip and tires start to turn at a slightly higher rpm putting more power to them.

I used the pink spring. They send two choices Pink and red but the red was another 400rpm higher hook up and that might be to much.

 

if i was in some very high stress places with mine and the slighly bigger tires i would still burn the belt in low range. specially if there was alot of mud, grass, and water and yes it would be in low range. if i would be able to hammer the throttle a lil harder it wouldn't slip but if i tried going slow and technical it would but my clutch kit fixed it [img]i/expressions/face-icon-small-smile.gif[/img]

 

Swampeater - So you basically have the same set up as me, except for the weights, I don't have those in. The power is sick, isn't it!

Did you have to remove shims, and did you change your belt?

I noticed on previous posts that you were asking about the brute 750 belt. I was told by the local kawy dealer that it's different then the brute 700 and prairie 650 belt, that it wasn't interchangeable, different angle on the primary and secondary, not sure if this is true. The AC 04 and 05 have the latest 650-700 kawy belt.

 

yes I did put a new pb700 belt and I had 2 equal shims and removed one of them. It will spueel a little when not moving in gear but it is worth it! Last weekend we did a real nasty mud ride and it was the first one that I didnt worry about the belt taking a dump.


04 650 AC
EPI Red Secondary
EPI Pink Primary
1 set of EPI "Belly Buster" weights
High Lifter 2" lift kit
High Lifter CDI Module
28" ITP mude lites
2500# Winch with pully block

 

When I took mine apart, I had two 1mm shims. Took one out, setting the tension at 22mm, kept the stock belt. The belt cherped and got worst by the mile. Took it apart a second time, removing the other 1mm and adding a .8mm and a .6mm again keeping the stock belt. This gave me a belt tension of 24mm.

Still cherps on rare occasions but she's tight and runs like a top! Hopefully yours will set in instead of getting worst, but if you don't mind the cherping, your good to go!