what i would do is since its easy put the shims back in, given that there are none there+ they are the shims that go there,inside diameter should match the diameter of the shaft(i have 2)see if its fixed,if not then go from there. also carefully examine the belt+ make sure there is no contaminants anywhere,clean it up.

 

Well, I do have the cover off so I'll try it. I'll put the shims back in and run it around the yard like that and try to see what's going on down there.

 

OK...................

Just for the heck of it, I replaced the 3 shims behind the secondary clutch (they fit just like they should, imagine that!) Anyway, the belt is VERY shiny on the sides. I didn't noticed any "hour-glass" impressions in the belt like it had sat and burned for a while. I put the secondary clutch and belt back on and ran it around the yard without the cover on it. The low speed take-off "shudder" I was experiencing before is gone. The primary clutch gets smaller and the secondary clutch gets bigger when I accelerate, I guess like they are supposed to since I have never seen them before and don't have any experience to compare it with. BUT there is a lot of squealing and racket coming from the belt when I accelerate, definite slippage! I neutral, I can rev it up and let off and hear a little squeal then also.

I'm beginning to think with the shims being off I had a definite alignment problem, causing the shudder, but now I feel it's just all worn belt. Could a worn/slipping belt cause it to have little to no low-end power?

Any comments/suggestions/insight/DEFINITE SOLUTIONS???

Thanks,

Ernie

 

Are you sick of me yet? Think of the shift process on a quad the same as a ten speed bike. When the belt/ chain is on a smaller diameter drive and a larger diameter driven you go slower and have more power. so, the primary clutch at idle has the belt at a small diameter and the secondary rides high and a large diameter. What I'm getting at here is that if the belt is stretched and too narrow because of age and wear It will not be in the correct position in the clutches. The same thing as say starting out in fifth gear instead of first on the ten speed. This will dog down your engine on low end , the same as your legs on your bike. Get a new belt and I think you'll be happy. Doc. For all my critics. Have at it.

 

that I can understand! Thanks doc!

Getting a new belt ASAP and see how it goes. Any difference in belt manufacturers? (Polaris? Dayco? Gates?) I can get a Dayco belt at Advance Auto Parts for $37 tomorrow. Polaris is $48 and either pay shipping or drive 3 hours round trip Saturday.

Ernie

 

I don't have an opinion either way on belts. Doc

 

I'll pick up a Dayco belt at Advance Auto afterwhile, if they have it in stock. If not, they'll have it tomorrow. Either way, it only costs me $37.77 and I don't have to drive 3 hours for it. I'll let you know how it's doing when I get it.

Ernie

 

Well I replaced the belt and it DOES perform much better. But I still have a heck of a noise coming from it when I accelerate hard. It doesn't make this noise when I accelerate slowly and I can put the rear end up of jack stands and hit the throttle all I want and it doesn't make any noise. It definitely sounds as though it's coming from clutches, I just can't really determine which one

 

In case anyone was wondering...................

The problem(s) turned out to be 2 things: (1) The torque-limiter/torque-stop was WAY out of adjustment. Now adjusted properly. and (2) the ramp buttons were toast! Replaced the ramp buttons also.

Between the new belt, proper torque-limiter adjustment and new ramp buttons, this thing will climb a tree now! It ACTUALLY scared my 10 year old son and he's jumping ramps 8-9 feet high with his dirtbike! As light as the TrailBoss is, it will get squirrelly real quick.

 

Excellent work Johnson, carry on. Doc