My employer provides a sportsman 400 4X4 to use in a number tasks. I of course use it for a personal riding too.

A few weeks ago, I noticed that the belt would start slipping in high range and would "jerk" in low range (maybe "grab" is a better description).

A number of us use the machine throughout the year, some are unfamiliar with ATV operation and I have a feeling that it is run in high range when it shouldn't be, etc...

Anyways, I removed the clutch cover and operation was smooth with rear tires off ground and in neutral. Primary closes as secondary opens, etc. but I could see that the belt was wearing. Picked up a new belt assuming this would solve the problem. No dice.

After installing new belt, problem is still there.

It seems that the secondary is opening to fast, or the primary is closing to fast. In low range when accelerating, clutch will "grab" early on, then lose momentum and start slipping at higher RPM's.

In high range, if accelerating quickly, belt will slip and you can hear it "squealing". With gradual acceleration to reach top speed, belt will maintain speed until a hill is reached, then it will start slipping.

I hope that describes the issue.

Any adjustment that can be made or possible worn parts that I should start inspecting?

Thanks for the help.

 

Probably best to have the secondary ramp buttons checked out,with multiple riders I find this a lot where the buttons are rounded or burnt up from using in hi range at low speeds which can cause clutch operation as you describe and can also glaze another belt if not repaired. Good idea to blow out the belt dust from the clutches and check clutch alignment also. OPT

 

welcome to the forum. sounds like the ramps(buttons) in the secondary are worn or the spring has issues. pull secondary off to check.

 

WOW!

Thank you for the help and the welcome.

Old and Stendori posted the following:

I've never torn into a secondary clutch, but am more than willing to! Are the ramp buttons an obvious part, where are they located, and how can I tell if they're worn?

Thanks again.

 

Best to have a manual,as there is tension on the rear clutch spring and after you remove the circlip the helix will unwind. Or you could check some of the older posts on rear clutch repair. The ramp buttons are underneath the helix on the clutch sheath. You can tell in a jiffy if they are worn! OPT

 

Great!

Thank you sir, I'll do some searching of the forums and give it a try.

 

worse case you can always pull the clutch off and take it to a dealer if need be.