Hello all,

My wife rides a 92 Trail Boss 250. We have had issues where this unit doesn't pull well at low RPMs. I have found that most of these units dont have and abundance of low end torque but this was a little excessive. After more research on how these PVT units operated I found that I have serious belt deflection issues. Put it this way I can touch the top part of the belt to the bottom. [img]i/expressions/face-icon-small-shocked.gif[/img]

I know the specs call for no more than 1 1/8 in.

Well I break out the Haynes manual and find little on clutch belt adjustment. From what this book says is you remove shims to tighten the belt and add them to loosen. Well thats fine and dandy, but I cant seem to find any shims ( I may be looking in the wrong place).

What should I do?

 

You actually have to remove the secondary clutch, and disassemble it a bit to get to the shims they're talking about. Do you blow out the clutches on a regular basis? Also, when was the last time you changed the belt? You can periodically take brakecleaner, or Acetone on a perfectly clean cloth, and wipe the faces of the clutches to clean the contact surfaces.

 

your polaris dealer can have them (shims),they're about 3 differents
wide to choose from,i wouldn't go any higher than 1/8 on top of secondary
for any top end lost.

 

I bought the atv in Feb. I havent done anything with the drivetrain. As far as when speaking of secondary clutch are you talking about the driven clutch?

I haven't performed any type of maintenance to the clutch.

I found that there is some play with the weights.

Do I need to have any special tool to remove the driven clutch?

Some many questions. So few answers!

 

yeah secondary meaning the driven clutch and the clutch remover isnt usually needed..

 

Most of the time you dont need to have a puller for the secondary. If moisture hasnt entered there before, then it should pull off when you remove the bolt. If you have the manual it should show you how to disassemble the secondary (driven) clutch. One thing no one has mentioned, YOU MUST leave at least one shim between the 2 clutch halves. If it has the original belt, I would replace it first and adjust from there. The belts dont stretch, merely they wear down and thinner, thus riding lower and changing everything.

 

Thanks for the help everyone.

The belt looks fairly new. The one thing I was wonder also was how much play should the weights on the primary clutch have?

I was under the impression that you adjusted the belt with the primary clutch. I will tear it down in tha morn and see whats going on. That belt has WAY too much play.

Is there any other ways to lighten this unit other than going with lightweight rims, handle bars and bumpers? I would like to shave 30 - 40 lbs off of this unit. It just feels top heavy and sluggish through twists and turns.