Please help !

I have a Scrambler 500 4 x 4. Recently I had it in for service for new spark plug, idle adjustment, choke & throttle cable, fluids, etc. AND, to have them look at it to "see what it needed". I was told it needed a new drive belt and new clutch buttons or ramps. All these repairs services were done and upon pick up it seemed to be OK.

I rode it less than four miles and got stuck. Black smoke, burning rubber smell and the clutch area black cover was very hot. The motor ran but it seemed as if the belt was slipping or burning up. I brought it back to the shop for them to look at it and repair it again. And, I did notice that it was slipping when in reverse that morning as I tried to leave for my deer stand that morning but I thought it was due to being in deep leaves. It wasn't, the ATV had no power when in reverse.

They told me that I must have been running it through mud or otherwise went in that direction however, this was not the case. I use this ATV to simply ride to my deer stand. I don't "go muddin" or racing with it.

They also told me that the problem is that the wheels & tires on it are larger than the original size and this puts too much stress on the clutch buttons and causes them to slip and burn up. However, these wheels & tires have been on that ATV for about five years without any issues.

Prior to bringing it in for service and to have it "checked out" I had no issues with it's power, belt slip, clutch slip or any such issue.

My questions:

a. What would cause these new buttons to slip and burn up in just three or four miles?

b. Did this damage my new drive belt too?

c. How do I know that I can count on this ATV in the field?

d. Would larger tires be a problem on a 500 cc ATV to cause this problem when it never did before?

Please advise and thanks in advance for your help !

 

Look at the belt in relation to the clutches. The belt while running should be centered on the front clutch and not riding up or touching either inside or outside sheath,plus the rear clutch should be still or barely turning.. Good time also to take a pry bar and see if you can lift up on the front engine mounts plus see if either rear mount has separated. If a mount separates it can throw the clutches out of alignment. Clutches may just need to be shimmed to align,but sounds like the belt needs to be replaced if their other work has been done properly. If it is a clutch alignment problem,the dealer should have caught this. Some dealers love to not warranty their work because it may have larger tires,etc and not stock. Not having a low range can be a factor on Scramblers,but I've worked on plenty with over size tires and didn't have clutch problems. OPT.

 

Thanks much !
BTW, it's a 2006 model.
Rear is chain drive, front is shaft drive.
The drive belt is new and was replaced with the clutch buttons together.
I have not noticed any issues that had me concerned about engine mounts being broken when riding.
How can I tell if I need an engine mount and how often do they break?
Is the mis-alignment problem the most likely cause of this issue?
I am going to pick it up tomorrow.
I plan on test driving it there in their lot and especially up their steep drive as this would cause slipping if it was going to happen.
They told me that the large tires are a problem but they are only about two inches larger and the thing ran fine with them for about five years. Plus, they said that it's not supposed to be used for hunting like I use it for as it's supposed to be a racing type ATV. However, when my dad owned a gas station and we had a race car I can tell you that we never broke parts on the car driving it slow.
What should I say or ask them?

BTW, thanks for your time and expertise. I can tell you that life is a circle because, like you, I provide similar advice on another forum to other people in my area of expertise. Actually, I enjoy the opportunity to help people solve their problems as to me it's self rewarding. So, once again, thanks much !