Hi, I have a 1992 Polaris Trail Boss 350l I want to put a clutch kit in it. I'm just getting more and more confused about the different things on other forums and I thought I would look here for help. I have the stock tire size but I have kenda bear claws from the stock tires. I ride primarily in mud and snow. When it pulls hard the clutch slips and the engine revs out before the secondary's can catch up What can I do?




James

 

Sounds like either the belt has stretched or the ramp button are worn in the rear clutch if it starts slipping and engine revs. Item#3. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse

 

Would a primary clutch spring help?

 

Not if the rear clutch is the problem. Pull the clutch cover,inspect the belt for slack and burnt spots. Slack should be no more than 1 1/2" when belt is pressed down in the middle.Rear clutch has to taken apart to replace worn ramp buttons along with front clutch for guide button replacement. If you're not familiar with clutches and tools required a good manual can help. Don't know if this link works,but worth a try.DOWNLOAD 1985-1995 Polaris ATV Repair Manual ALL MODELS - Download ...

 

how would I know that the buttons are worn out?

 

Front clutch button wear would usually cause back and forth slack on the clutch spider. Plus check for any grooving on the inner clutch sheath where the buttons glide. Rear clutch has to be taken apart to see the wear on the ramp buttons. You can usually tell if they're worn also by just holding one clutch sheath and turning the other. If you hear/feel a grinding,the ramp buttons are toast! Again the 5 buck manual link I showed you can help you if you plan on working on your own machines.

 

Thanks!!

 

I finaly got time to work on it and I have alot of belt slack I can also easily push in the primary an inch is something wrong there? I also want to know how to remove the secondary and get it to stay on and not fly off when I put it back on? Thanks again

 

Replace the belt. The secondary is held on by a circlip. Knock down on the helix enough to remove it and the washer.Don't be alarmed when the clutch unwinds! Pull the helix up and remove the spring,ramp buttons are exposed.Blow out the clutches in an open area.Replace the ramp buttons,place spring in 2nd position of helix,align helix with clutch shaft spline,lower and place bottom tab of spring in #2 position.Helping hands or clamps on next step. Hold the helix down a little with your stomach(bigger stomach the better!) while holding bottom sheath, turn top sheath 1/3 turn counter clock wise,then helping hands or clamp the c clamps on BOTH sheaths locking then down,then knock helix down all the way. Replace washer and circlip. Remove c clamps and clutch will snap back.

 

I got the buttons off and they are slight ly orn and they are grooved up and so is the helix. Is that a problem?