My problem is this, I have to give alot of throttle for the machine to move. can peg the throttle lever and the machine will only do about 20mph.
Heres what i recently did to the ATV. Changed all fluids, replaced spark plug, and replaced belt.
The reason I replaced the belt is, last summer I had gotten stuck, and had noticed the belt starting to slip and the smell of burning rubber. Once unstuck, I had no problems, just figured I'd replace the belt as a precautionary measure. The old belt showed minor signs of wear, probably normal. But I replaced it anyway. I also cleaned both pulleys and checked for any abnormal wear, pulley scars, clutch, etc.
Now, since replacing the belt I've got this issue.
Could this be related to a throttle cable adjustment?
Is it possible I put on the wrong belt?
Is it possible the belt is installed backwards, meaning does it get installed in one direction only?
When I jack the ATV up, remove the cover, put it in gear, all appears to operate normally. There is no belt slippage at all.Put it on the ground, give it throttle, goes nowhere fast, the rpm's go up but the machine doesnt respond the same as it used to.
Now I know it has to be something I did replacing the belt, because I've never had this problem before.

 

yes the belt can only be on one way or it will not work had that problem

 

when installing the belt, you should be able to read the writing on the top of the belt.

Actually sounds like you may have put on the wrong belt.

 

check the secondary clutch to see if the spring is broke or out of its holes or maybe the buttons are worn out of the secondary under the helix.

 

The belt I put on was from NAPA. They cross referenced the Polaris part #.I'm going to get a belt from the dealer and see if thats the fix. Like I said, prior to installing the new belt,I didn't have this issue. I installed the belt both ways and the problem still persists.I ran it without the cover and everything seems to be working as designed.Its hard to tell if the belt is slightly slipping when driving it. I can tell you this, at about 5300 rpms, i'm only going about 20 mph.
I compared both the new belt and old belt, and they seem about the same in size.
The machine is running great otherwise, good idle,adjusted throttle.
I did replace the Polaris air filter with a K&N filter, this shouldn't affect anything right?
Especially since I had to make a minor throttle adjustment to accommodate the new filter?
I bought the machine new, and I hear talk of a 04 and 04.5 model.How can I tell which one I have?
The machine has only 1200 miles on it, and doesn't get abused, mostly clean trail riding. I was stuck only that one time, when I smelled the belt burning.Just trying to add info to your diagnosis. Thanks.

 

04.5 has diff operated 4x4 insted of the hub's operating it it also has a fule gauge and tie strigh shift pattern and park i dont know if thear is any outher dif

 

Sounds like the belt they gave you is too long.Unless the belt has an arrow indicating direction it can be run either way,but if you take it off it needs to be installed to run the same direction.

 

I installed the new belt with the manufacturers letters facing me, then switched it the other way and it made no difference. I'm hoping the OE belt will solve my issue, although its $30 more than the NAPA belt.