Ive been plaqued by this hard shifting issue from day one. I brought it back to the dealer (under warranty)about a month ago and he claims they took out a shim to align the clutches. It didnt help at all.
I still have over a month and a half left on the six month warranty , not to mention the 3 year extented but rather than keep taking it back to the fools i decided to just have a look for myself. After taking the side cover off , i noticed some uneven wear on the inside of the belt. I then started the motor and noticed that after i rev it up the clutch does not always go back original resting spot (fully disengaged). Although it idles at between 1150 and 1200 the clutch still stays engaged about 1/8 to 3/16 of an inch. It will fully disengage when i shut of the engine. As best as i can tell , the belt seems to be rideing off to the one side of the clutch(away from the motor)i dont know it that has anything to do with the disengageing of the clutch.To me the belt seems to be too tight also. Another question i have is , is the belt supposed to run half way sticking up out of the secondary clutch? It just looks a little odd.
Anyways , if someone can take the time to look at my pics of the uneven belt wear and give an opinion of what might causing it , i would greatly appreciate it.

 

The pic of the secondary looks normal. Are the pics of the 'belt wear' the outside of the belt (hittin the cover somewhere) or the inside (uneven on the EBS actuator in the primary)? I've heard of people having creeping problems after coming down to a stop. What was happening was that the primary wouldnt release all the way (like what you described). A buddy had his primary rebuilt on his 500HO but it still would creep on him, so he got a whole new primary and that fixed it. If you still have any confidence in your dealer tell them what you found and suggest a new primary (not rebuilt) and see what they say.

 

like eab said about the riding high is normal. that belt wearing like that i wouldnt beleave it to right. looks like maybe somethings out of line. that would be a good indercation to me of being out of alinement. if the belt was too tight it would creep as my 500 did that once when the belt shrunk. replaced it and never had the problem again.

 

Thanks for your reply,
The belt wear is on the inside of the belt and toward the motor.
I have no confidence in my dealer so i will be going to a differant dealer as well as speaking directly to Polaris.
My dealer should have noticed what was going on with the primary instead of taking shims out or whatever was he actually did.
There are scuff marks from the belt on the cover just below the secondary if that relates to anything.