Hope someone out there can help me troubleshoot this problem. I have a 1997 Prairie 400 4x4 that I bought used in 2000. For the most part, I only use it during hunting season, with a few occasional rides during the summer months. It has been very reliable, but in the last year or so, I have had this problem with it. Sometimes, while in neutral, when I rev the engine a bit, a very disturbing noise eminates from the right side of the quad. As far as I can tell, it is coming from the clutch mechanism. It sounds like gears are trying to grab, and the bike occasionally tries to lurch forward when making this noise. It is sort of like something is loose and the centrifugal force of the rpm's is throwing it in the path of something else, making a definite, loud, clacking noise that subsides as the rpm's come down.

It usually happens when the quad is first started, but it occasionally does it when warmed up. After I put the quad in gear, it goes away and does not do it at all, no matter what speed I'm driving. Also, after I go through putting it in gear and then go back to neutral, it usually does not do it anymore even when again revving in neutral.

I have removed the cover on the right side of the engine, exposing the clutch assemble and driven pully. Visual inspection shows nothing out of the ordinary that I can tell. I did notice throught the inspection holes in the clutch assembl cover that, what appear to be counterweights have a little play in them. I don't know if this would cause what I'm hearing. I also did the test to measure belt deflection and it is approx. 28-29 mm (within the 25-30mm factory recommendation). Drive belt was replaced through the recall shortly after I purchased the quad.

Other than this noise, there are no real performance issues with this quad in either Low, High or Reverse. However, this noise is awful enough to give me a lot of concern.

Anybody ever experience this or have any suggestions???

Anything you can offer would be greatly appreciated.

Thanks. JimC

 

I would guess that the shift linkage is out of adjustment and that it is possibly slightly grinding the gears. It is very straightforward procedure to adjust this.

I might also guess CVT shoes are getting worn. They rattle more in neutral than any other time. If they are noisy but not really loose, then it may not be a problem yet.

My Bro has one of those 400s and we have had almost no mechanical problems (just a u-joint). It has been rolled twice, put sideways twice, and it hit something head on very hard once so we have had to replace a lot of stuff on it.

 

Thanks Nyroc. You 'da man. Shoulda thought about the shift linkage first.

While I had everything apart, I used an air compressor and blew a lot of crud out of the clutch assemble and driven pully assembly. After I put it all back together, it seems to be little quieter and hasn't made the noise again (yet).

I visited your website and used some of your tech tips regarding carb adjustments, etc. Everything seems to be running fine for now. You were right about this quad having very few mechanical problems. I've had it for more that three years and, until now, have had to do nothing more than change the oil and make a few adjustments. My nephew ran off the road once and hit a concrete drainage culvert with the left front wheel. threw him over the handlebars and then the bike rolled. (Thankfully not on top of him.) He was a little bruised, but OK. Tore the lower a-frame assembly off and bent the rim and handlebars. Ouch! $200 later, everything was back in order.

I think I'll leave things be for this year and look at doing some clutch and driven pulley work next year. By then, the belt is going to need some tightening. I was curious about a few things. I read the info on your website about changing the driven pulley spring to the EPI white spring. In looking at EPI's website, is the driven pulley considered the "secondary" spring or the "primary" spring? Also, if you change the driven pulley spring, do you also have to change the drive pulley spring to match? You indicated that changing the shim would tighten the belt up some. Can you tell me how much? I may end up having to change shims. Right now, I measure about 28-29mm.

While I'm at it, I may as well go ahead and replace the CVT shoes. Do you know if there is a "kit" that will contain all of the parts I will need to change there? If not, what all does need to be replaced? Just the shoes, or anything else? And, of course, the big question here is "Is this very difficult to do?"

Thanks for your feedback. I appreciate all the help I can get.

jimc

 

The driven pulley is what is also referred to as the secondary (rear). The 400 CVT is not adjustable per the instructions in the repair manual (which I saw once but do not have currently). There was one shim which appeared to have no other purpose other than for adjustment. You will see it when you get there. Tighter is better. I will take my brother's shim out whenever I see it again. It isn't very thick and probably won't do much.

MY brother's 400 used to go 55mph with lightweight toilet tissue tires (dunlop). With 26" bearclaws it began to feel like it was bogging (too low rpm) and wouldn't go very fast. When we added the white spring, the power came back and it has umph, but it won't go over 48mph. If this is corrected for tire diameter, it still isn't 55mph. But, that isn't important to us. You do not have to change the drive pulley spring. The driven and drive pulley springs work together (added) against the weights. It is better to add tension to the driven pulley spring to get more belt side pressure and therefore less slippage. It worked out very well for our P400.

I do not know of a shoe kit. EPI might have put a kit together. I haven't looked. Our P400 only has 1100 miles. I think the shoes are not overly difficult to install. To be honest I have not ever replaced them. I know what it takes to do it to a 650, I would guess that the P400 is about the same.