sounds like a game plan, I'm gonna fab up some tools tomorrow. I'll let you know what the outcome is. I was thinking about going with a Dayco extreme belt.

 

I've been following your thread and it's been a couple of days. I'm curious if you've made any progress? I am having the same issue with my bike creeping... I checked out the clutch and sure enough, the secondary is spinning when the bike is idleing in neutral.

 

Honestly I cannot find a bolt 3/4" and threaded all the way. I have checked our bolt carriers here and Ace hardware, tomorrow I am gonna try to hit home depot or Lowes and try my luck. Other than that I haven't made any progress about my clutch creeping. No I do know one thing, my belt is glazed on the side towards the motor so maybe I could be lucky and shim the secondary but I still can feel my primary hanging up on the shaft when I push the clutch in with my hand it goes in ok but when I let it out slowly I feel the little arms that come out hanging up on the shaft so it has to do with those catching. The only thing I can think of is that the maybe the fiber washers inside are done, or that the shims or something moved. I will post here when I finally get a bolt so I can take off the primary and break it down.

 

 

I have a piece of all thread (fine thread) that fits. You wont find it at Lowe's or Home Depot.

It threads in just fine, but I cant seem to get enough torque on it to break the clutch loose. I'm clamping on a pair of vise grips onto the threads, and sticking a metal bar through the clutch to keep it from spinning. I'm worried that I might break something on the clutch at this point.

Everyone I talked to about the clutch removal suggests using an impact wrench. The all-thread doesn't have a head on the end of it so I lost again! Argh!

 

Trailboss--I was able to remove the clutch.
I looked for a coupl eof nuts to jam on the end, but I was only offered a pack of 20 for $30--no good!
I did some more research and grinded off some more of the threads on the end of the all thread.

I found a post that suggested pumping in some grease into the hole from a grease gun and that this would create a hydraulic effect and assist in the removal. I'm not sure if this is true, but I did manage to get my clutch off with the all thread and a pair of vice grips!

 

what is an all thread. Is it like a threaded rod.

 

Yeah... that's what I call it anyways... a peice of rod stock, threaded from head to toe!

 

I think Lowes and some auto places around here have that. I just need to know the exact size like I know the bolt is a 3/4" but I need the number for the fine threads like I think 10 is a course number.

 

Your Belt should be a Polaris 3211069 so someone changed belt for some reason.

Sounds like you have this guys problem http://forums.atvconnection.co...rd1=clutch%20alignment

Here a video of a guy whipping off a primary pretty quick. http://www.youtube.com/watch?v=8_HhKSY3Ro8

Starter removal tip for your next project.[img]i/expressions/face-icon-small-smile.gif[/img]

My Manual told me to get special tools and remove primary and secondary clutches to remove back belt housing plate just to make room to remove one remaining bottom starter mounting bolt!

Instead this is what I did. I took out the air box and removed the top easy starter mounting bolt. With the bottom stubborn mounting bolt you just back in off until it hits the backplate of belt housing,it will not come out but will disconnect.
Than I used large channel locks and turned the start clockwise until the bolt was at the 12 O'Clock position and slipped the bolt and the starter right out no problem.

I can,t believe my " Clymer" manual wanted me to tear down half the bike to remove one bolt!

BTW it turned out one of my starter bushes was sticking so I cleaned it up and it works great now. I also put that blue gasket goo everywhere a o ring was, to see if that may help water proof these Polaris starters once and for all.