ANOTHER Sportsman 400 clutch question. I have read, literally, dozens of threads on here trying to find a solution. I am still not satisfied so it is time to post up.

2004 Sportsman 400 with about 1200 hours. Last trail ride it begin NOT climbing up hills. It's the wife's machine and she was BARELY making it up even some small hills. There was noise coming from the area of the front clutch, like a rumbling noise and you could basically "hear" that the belt was vibrating around.

I got on and drove it back off the trails in LOW gear. I could actually feel the belt (or clutch) slipping and when it would wind up I could feel it smooth out and engage and it would run fine.

I presumed the belt was fried. Before I put the new one on I ran it with the cover off. The belt definitely had a "vibration" between the clutches. It revved up and down OK.

After putting on the new belt there seemed to be NO change. The old belt appeared to be in great shape, btw.

Ran it around the yard and it did exactly the same thing. So, now I'm thinking there is an issue with the clutch. How do I know? Can I test the clutches? Should I take them to dealer and let them look at the clutches????

I am about to go back to garage and take cover back off and then remove both clutches. I will also look for any wear or grooves in the clutch faces.

Oh, I looked at a couple videos on youtube of the belt and those belts ran WAY smoother than mine did while running up the clutches.

Anyone that can offer some suggestions????

 

Here is the BEFORE video:

Picasa Web Albums - 11806167628038391... - LT80 Build Pics


Here is the AFTER video:

Picasa Web Albums - 11806167628038391... - LT80 Build Pics

 

pull off the clutch on the transmission, tear it apart, and look at the button ramps, theyre either white in color or brown, if they are worn then it'll feel like your belt is slipping, they're underneath the helix in your secondary

 

You must be a mind reader. After reading about all these "buttons" on the clutches I decided to find out what in the heck everyone was talking about. Since the rear clutch comes off easier, I took it off first. When I shook it I could here something rattling around inside so I tore into it.

I suppose these USED to be buttons???

http://lh5.ggpht.com/_G-mcbMVHqPE/TE...0/DSCN0106.JPG

http://lh5.ggpht.com/_G-mcbMVHqPE/TE...0/DSCN0108.JPG

 

Also, here are some pics of the helix. Is there a certain amount of allowed "wear" on these things? If so, how do I know if there is too much?

http://lh3.ggpht.com/_G-mcbMVHqPE/TE...0/DSCN0109.JPG

http://lh3.ggpht.com/_G-mcbMVHqPE/TE...0/DSCN0110.JPG

 

you have found your problem lol. as far as the helix goes if you clean up the ramp section where the shoes slide and they are not all grooved out then most likely it will be fine. new shoes and belt w/ a completely clean clutch it should be fine.

 

Be sure to pay attention to wher the spring ends are and pre tension the helix 1/3 of a turn before you put the snap ring on.

 

Looks like you found the main problem. Be sure to clean the primary and inspect that the best you can while you are in there.

 

That clutch needs a rebuild for sure, looks like the belt dust took over. Need some scotch brite, cleaning solution, and tools to dis-assemble both clutches. Rebuild them and should be good to go

 

I may have a complete secondary clutch.Drop PM if interrested