I have a 00 Magnum 325 that grinds while putting into gear from ‘N’. I have replaced the pri spring and belt. I even keep old belt on it that has over 2" of play and it still grinds. The secondary clutch runs all the time while in 'N', even with lowering the idle down to where it will die. I have removed belt and spin the secondary clutch. It spins free. When I spin it it just keeps spinning. The belt is so lose and by it just setting on the primary drive it spins the secondary. Is it normal for the transmission to spin freely or should it have a little resistance to keep it from spinning just by belt seating lose on pri. clutch drive?

 

the secondary will spin freely when in neutral w/ out the belt on. does this bike have the ebs on the primary? sounds almost like a bad ebs bushing and the bike would want to creep ahead while in gear. the engine mounts may be broke or out of alignment. imo

 

No ebs on this. It is the correct distance between Pri and secondary clutches and belt is riding in center of pri clutch. (not rubbing on edges). Just the weight of belt laying on the center of pri. is allowing the belt to spin the secondary. That is how freely the secondary spins.

 

how much belt deflection do you have?

 

I checked for broke engine mounts today. They are fine, not broke.
Belt deflection: old belt has 2"+ and new belt has right at 1 1/2" but I had removed a washer and got it within limits. I have since put washer back in because of the grinding issue.

 

it sounds like w/ 1 1/2" is about right. so does it still grind w/ the washer back in?

 

Per manual deflection should be 1 1/8 - 1 1/4. Yes it grinds with the washer back in. I think I'm going to recheck the shift linkage adjustment to see if it is off alittle to see if it changes anything.