Hello to all...I have a '05 Scrambler 4X4 with the HSP package (blue clutch spring, jetting, K&N filter & pipe). I just changed my belt and now have issues! After installing my new belt I'm not able to reach top speed, in fact only able to reach approximately half speed. However, I have more torque than ever now (would love to keep the torque, but get my speed back)! Once I reach about mid range, but throttle fully engaged, I gain no more speed. Just sounds as if engine is maxed out and making a winding sound. When before I would accelerate fully, even with a partially shredded belt. The part # for the belt is 3211077 (got the belt from local Polaris dealer). I pulled the clutch cover to ensure my drive clutch was fully engaging while driving......and it is. Also check my transmission fluid.....good to go. Did nothing else but changed the belt by pulling the driven clutch (rear flywheel) and reinstalling with new belt.?. Had the carb apart few months ago just for inspection.....it looked good as well. Any suggestions before I take it in????? Thanks.

 

Could a piece of the shreeded belt have gotten in the clutch and keep it from engaging fully?

 

Just went out to look again...with flashlight & mirror could not find anything stuck within clutch. Also double checked all the spacers/bushings and the three arms within clutch to ensure they were not binding. All were good to go.?.

 

Sounds kinda like the secondary is stuck and not shifting out. Pull the cover and rev it in neutral and make sure the secondary is shifting out

 

When I rev it in neutral the clutch compresses and tightens the belt. It sounds perfect in neatral, but as soon as load is on it (in gear) and about to mid range it hangs up. Could the secondary just hang up when in gear and going?

 

Back again...I better understand the secondary clutch. When I rev it up the secondary belt area should close up some, correct? This is due to the spring within expanding and pressing the middle peice of the secondary cluth outward. Does this sound correct?

 

When in nuetral the primary will close and the belt will ride up in the pulley, the rear scondary works the oppisite, as the machine revs it will open and the belt will ride in the bottom of the pulley. Did you get a Polaris belt or 1 of the wrong aftermarket belts?

 

First off you shouldnt have to pull the secondary to change a belt.It should go on by putting it over the primary then roll over the secondary while you turn the clutch.Sounds like you have the wrong belt.With it sitting there not running does the belt barely stick over the top of the secondary sheaves?If so you may need to take the secondary apart and check the spring and where it is set.

 

Ok...understand the clutch concept now. And both cluthes are working. The belt is a polaris belt bought from the dealer. I also cross referenced the belt part # up online and it matches.

Yes the belt does barely stick over the edges (sheaves) of the secondary clutch. How or what should the spring be set at? I'll tiple check the belt this evening and then pull the secondary apart. A huge thanks for everyone's comments.

 

Stock 500 Scramblers are set at the factory 1-1 but I recommend 2-2 for better backshift