I don't like the grease idea... I mean if water makes the belt slip just imagine a little of that grease getting on there[img]i/expressions/face-icon-small-tongue.gif[/img]

 

Well I have the cover off now. I discovered a new problem. The same thing actually just happened to my buddy's Sportsman as well. His is an '02 400, same as mine. The belt on mine has actually worn a groove into the primary clucth, on both the inner and outer sheeves. His was so bad that it made his wheeler bog down in high range when he was running low rpm's, going from a dead stop, I haven't really noticed a major difference in the low end power of mine, but I'm curious if this is a commen problem with Polaris's. I've rebulit a primary before on one of my old sleds, but just the two sheeves would cost around $200-$250 I would guess. Plus I'd have to buy a clutch puller as well. Has anyone else ever experienced this kinda problem before?

 

I had that happen on my 425 magnum after I put a Goodyear belt on it.Now all I will run is Polaris or Dayco.Your best bet is to get on ebay and find one that was taken off to be replaced with an EBS system or someone parting ot a wreck.You can get good used ones for less than $100. While you have the clutches off you should go ahead and check the secondary buttons out .They could have broken and caused the cluth to lockup and cause this probblem too.

 

I seem to remember reading that there was a time when the Sportsman had some warpage problems with the belt cover. Some whiney, anti-Polaris guy brought it up after having a problem with his. I also read that Polaris had changed the inner structure to make it more rigid. I'd consider looking into upgrading and you can also buy an oil change kit that comes with a bunch of goodies including a new gasket.

My 2004.5 400 and 500HO both have red drainage plugs.