I have a 2005 Sportsman 500 and at about 600 miles I blew the drive belt, it was covered on warranty and they supposedly checked alignment and cleaned the clutches. When I got it back I took it out for a ride and tried to climb a ditch that I had climbed lots before(I did use Hi gear, but so did all of the guys I was riding with) and the belt just smoked and I did not even move, ever since that time I felt vibration from the clutch and loss of power and topend. I took the cover off the clutches to inspect the belt and noticed that one spot on the belt sat lower in the secondary clutch(Probably from getting smoked). So I got a new belt and cleaned up everthing and it ran great, lots of power and I got my topend back. But now I can smell buring belt all the time, even driving down the road I smell the belt slightly, and I am starting to notice a decrease in power and topend again.(belt only has about 100 miles on it). What could be wrong? Clutches misaligned?

Thank's

 

I would wonder if it has the proper belt deflection. (The distance between the 2 clutches may be too close/far apart.) (Alignment is having the 2 clutches paralell to each other.)

 

The belt should be taunt, no deflection on an EBS machine.

You have a flat spot on your belt and should be using low on inclines at slow speeds or from a stop.

Jim

 

If you are going from a stop in High Gear up an incline hit the throttle quicker for a faster grab on the belt, when it engages slower the belt has more time to slip

Try running the quad with the belt cover off and see how the belt looks when idleing, it shold be free the the clutch on both sides, revv the engine a bit and see how the clutches act

 

Is it normal for the belt to sit above the secondary clutch about an 1/8" of an inch all the way around or should it fit flush?

 

most sit 1/8 inch above on the secondary clucth

 

When I put it in "N" and rev it up it hesitates between 3500-4000 RPM for half of a second then it revs up to where it should. It seems that when I am driving it won't rev up and this is why I am burnig belts? Why would this be? Is the secondary clutch not opening properly?