Have a 2000 Scrambler 500 4x4 stock. I put a AAEN roller clutch kit and primary clutch kit in it . It has no top end . It seems to be turning to many rpm's on top end . The primary kit came with a red spring and 55 weights . The roller kit came with the new helix using the stock silver spring. Anyone else using one of these kits from AAEN? Let know how it works !!!

 

I sounds like the helix wasn't properly indexed when the driven clutch was re-assembled. Sorry to say, but it all has to come apart again to make it work correctly.

 

Yea, if you don't get the right amount of pre-tension on the secondary it will run like crap. Check your belt for wear if you rode it much like that.

Turn the inside sheave counterclockwise to set it.

 

I set the sping to the setting AAEN recommended first which is 2/2. Then I tried other settings no improvement. Also I've noticed a vibration on top end. It does it in neutral too. Do you think it could be a unbalanced clutch. It has done it since I got it the dealer doesn't know what it is? He says its normal - I don't think so !!Rode a 99 500 no vibration.

 

Olav Aaen has made a point to explain about putting the rear clutch together correctly. You kind of have to twist the housing as you compress it so that the rollers are on the correct side of the helix. If installed wrong the clutch would probably perform worse than before. An additional problem may lie in the position of the rear spring. The recommended setting seems to be the #2 hole on both the sheave and the roller housing. Adjusting this spring varies the acceleration / backshifting properties. The real culprit however might be the front spring. The higher preload allows higher engagement speeds, higher operating RPM's under load and in most cases a lower top speed.

I have the megaphone exhaust and a 42mm carb which produces more power and allows the motor to rev a little higher so some top end is recovered. I pretty much have the same setup, clutch wise, as you do with the exception of the rear spring. I have a Aaen blue spring set slightly different that recommended. I am still trying to find the sweet spot which unfortunatly is trial and error.

Chris Picciotto
99 Scrambler 500

 

There is really no way to tell unless you have a tach. I'ts impossible to tune one without it. The proper pre-tension of 25 lb. is very important. I've always used the blue secondary spring in the 2nd hole. Also, make sure the clutches are properly aligned. That could be the culprit right there. When we did one of ours, the shims had to be changed considerably. Once properly set up you will find it difficult to ride an atv without a roller setup. The change in performance is considerable. The drive spring has very little influence except for engagement.

www.GoDigital-Design.com/SchultzMotorsports

 

Doc,
The helix in the secondary clutch has to be rotated about 1/4 turn to properly set the preload. It's a REAL PAIN to try to do by yourself, an extra pair of strong hands will help,( I used a Black & Decker Workmate to do mine )so that you can re-install the snap ring. as for the vibration, check to make sure that the X's are aligned on the primary clutch, they're easy to miss if you don't know to look for them.
Hope this gets you taken care of.

 

Take a 1x8 drill a hole in it a little bigger than the snap ring kneel on the board across the clutch to hold the compression down while you replace the snap ring if you are alone.

 

Thanks for the info fellow riders . That is how I set up the driven clutch . I'm thinking that maybe the vibration is messing the shifting up. Took it to the dealer again to see if they can figure it out. They called polaris to get some answers. Hope they can help. Also called the company I got the kits from . He was going to call Aaen to see what they say. THANKS FOR THE INFO APPRECIATE IT