New owner of a 2002 sportsman 700 and need help witha few questions
#53
OPT when you measure the clearance between the one way clutch and sheave, do you slide the one way clutch all the way towards the engine and measure the gap now between the end of the clutch and the sheave? If that is true, I'm way over .020. So it looks like I got to tear the spider off and see what that PTFE and brass washers are doing?
#54
You can slide the one way either direction and measure. I just slid it to the outside and measured between the fiber washer(or in most cases what was left of it) and the inner sheath. Yes over .020 can allow the belt to creep over and touch the inner sheath. This just puts constant pressure on the driven clutch. After repair the rear clutch may need to be shimmed out to make sure the belt runs center of the one way. Plus don't overlook broken or soft engine mounts,especially the front one.
#55
#56
Front engine mount(#38) is the most common one to separate or get soft and weak as it takes most of the torque stress from the engine.The engine can flex a little which can cause clutch/belt problems also. Simple pry bar test by pulling up and pushing on the engine from side to side. They can be broken and you may not know it as each side washer and bolt are molded into the mount. Top and rear mounts usually don't give that many problems. Use 1 washer under the cup,slide it up against the one way and see if you have side to side play. That may be all you need or you may need 2 like the original poster used.
#57
Okay Got the primary apart. No PTFE washer at all. The one way ground a ridge into the sheave. can i lightly grind the ridge down or am I screwed?? Also the brass washer is worn paper thin; Not really cupped but paper thin. So the part number in the other post for the steel washers was 7556401; However they are too small for my shaft and wont slide on. Do you have the correct number? Also the engine mount passed the test, It's still good.
#58
Just take the brass washer in to any good hardware store and match it up with the same od and id steel washer. Get a couple that are .020 thick. You may just need one washer under the cup or two like the original poster used. If the ridge in the sheath isn't too deep you can use 600 or 800 grit paper to smooth it up.