Hey, I got an urgent problem, a friend of mine went on a ride tonite and his belt broke and got thrown through the belt cover. When he got the machine used, the belt cover had some heat warpage and the backplate that the cover bolts to was warped. The dealer that he bought it off of replaced the cover and seal but not the backplate and said it would be fine. ( we didnt notice the backplate was warped untill after we got it back from the dealer) So we took the dealers word for it and went on a short ride and went though a faily deep water crossing. When we went through the water his belt sucked water in somewhere other than the vents. It took alot to get it dry, but he ended up riding it out and it seemed ok. So tonite he went for a ride on the backroads and it was ok until just before it broke, it had a slight hesitation then the belt snapped and all hell broke loose. How bad is this going to be to fix, and how long will it take to fix, its the early (12:30 a.m.) morning of the 14th and we are going to badlands on the 16th as far as we can tell, we need a cover, belt, and backplate. Help..........

 

Some things to check - Check the rubber boot behind the cover that hooks the snorkle beside the engine and the one that hooks to the cover - ensure that they are zip tied or clamped and not torn. also if the cover was worn check the seal between the motor and rear cover for tears and the one betweem transmission and rear cover for sealing. If I was going through the trouble I would just replace them both. All that is required to change it is a 5/8s for the clutch and a puller for the clutch - retorque clutch to 45- 50 foot pounds. A Half inch to remove driven clutch just slide it off and note any spacers and washer behind it and return them - most have two little spacer washers and a little spacer as long as the thing does not want to kreep in gear should be ok. WHen replacing torque this to 17 foot pounds DO NOT OVERTORQUE. Then there are three philips head screws in the seal between the cover and motor that have locking tabs on them and three 10MM or 3/8 (tranny end of backplate) inch both usually work as the bolt are usually not very tight and come off using just a nutdriver again do not overtorque these when replacing just as tight as you can get em with a nutdriver is fine. The cover has 10MM or 3/8 bolts in it as well use a nutdriver to do the same and do not overtorque them when replacing them. I would get a can of clutch cleaner and clean the clutch up if the belt came apart and I would have the dealer take the driven clutch apart as there is usually strings of material from the belt wound up in the driven clutch and can cause it to wear or worse stick open. Hope this helps. The clamp head size on the cover if your has clamps is 1/4. A tip here is to take the four philips screws out of the floorboard and the left body panel off just snaps loose and just pull the floorboard out enough to get the cover on and off. this requires as you can tell a philips screwdriver and a 7/16 and make note of the spacer under the rear of the floorboard and replace it so that your body panel will have the proper clearance to snap back onto your quad. Actually this sounds like a lot but all can be accomplished in under and hour. Putting the belt on is as simple as when you have the Drive and Driven clutches reinstalled put the belt onto the Drive clutch and then just start it over the Driven with the quad in neutral and roll the belt over the pulley rolling it to the rear. Since I was changing belts anyhow I would put a sportsman 700 belt on it they seem to last a little longer and give you a little more top end.
Also I would put the new designed cover on there as it has a drain plug in the rear if you get water into the belt again.
Last but not least ensure your clutches are aligned and also while you have your back plate off check the rear motor mounts and the left front one to make sure they are not broke or warped and causing your problem.

 

We called weavers in Attica earlier today and they had all the parts and everything to fix it and also can have it done by sat. mid morning so it was dropped off today and we are picking it up on our way into badlands. Thanks for your help.