I HAVE A 95 SPORTSMAN 400. AFTER PULLING A LOAD FOR ABOUT 1/2 HOUR, THE BELT BEGAN TO SLIP AND THE PVT COVER LATER MELTED. I REPLACED THE BELT AND THE COVER. WHEN I DID A TEST RUN I WOULD NOT TURN THE WHEELS AND THE BELT FELT LIKE IT WAS STILL SLIPPING. I PULLED THE SECONDARY OFF AND FOUND THE BUTTONS WERE IN PIECES. I REPLACED THE BUTTONS BUT THE PROBLEM IS STILL THERE. ANY IDEAS ON WHAT TO CHECK NEXT?

 

how about the primarys buttons/bushings?

you may have gotten thewrong belt. have you pulled the cover off and reved the motor up in neutral to see if the belt is getting grabbed by the primary. also did you preload the secondary spring when you put the helix back in.

 

I DID PRELOAD. I HAVE NOT CHECKED THE BUTTONS IN THE PRIMARY AS I DONT HAVE THE TOOLS TO REMOVE IT AND I DIDNT KNOW THERE WERE BUTTONS IN THE PRIMARY.

 

its the right belt. it looks to be loose though. all but one shim have been removed from the secondary. should i try moving it at the engine mounts?

 

i think that depends on whether or not the primary is moving. did you rev it in idle? does the belt move.

if the primary is moving but not grabbing the belt I would look at motor mounts. if its not moving then theres the problem and its probable time to rebuild the primary. or buy a new one/ used ebay.

 

it moves and the bike will drive but very bogged down and very slow.

 

ANYONE HAVE AN IDEA OF WHAT TO CHECK NEXT?

 

if the primary is bad it will cause boggin problems. was the helix scratched up? if it had a large enough gouge to stop it from moving on the buttons this could be it.

 

YEA, CONTACT AREAS ON THE HELIX HAD DEEP SCRATCHES, YOU THINK THIS MIGHT BE IT THEN?