problem is on my dads 2004.5 sportsman 600, he was complaining how his engine breaking was not working as well as it should be, so I put on brand new polaris belt and now engine braking works great, but now its making a clucking sound slightly after its already moving, and I can feel it cluck, like if the belt is not hooking up right. I've put over 100 miles on the belt and no difference. The machine and clutches has well over 3,500 miles on now. Now what??

 

sounds like the buttons need replaced on the spiders, easier to probably take it to the dealer, since they will probably have all the special tools to do it, shouldn't take any longer than an hour to do it.

 

is this on the clutches?

 

could it be the clutch and old belt are worn together and now with the new belt the clutch has grooves and doesnt play nice with the new belt?

 

can barley feel and see curves on the primary.

 

You will feel a gear clunk, that is normal when you are on and off the fuel!
if it's clunking all the time under acceleration you have a problem.

 

take the belt off and then remove the clutch cover and try rocking the outer sheeve of the clutch to see if you have alot of movement. if so then it needs rebuilding.

 

stendori, what do you mean by rocking the outer sheeve of the clutch?

 

sp. rocks, watch this video and around 3 minutes into it you'll see the buttons that have been talked about and the bushing which gets worn out causing the rocking.