I think you need to follow an earlier post and get a clutch alignemtn tool or take it to the dealer if you do nto want to buy one. If the atv is creeping it is usually a matter of the belt being too tight. You have confirmed that the belt number is correct so the next option is to add a shim in the secondary to alow the clutch to run open at idle and create a shorter distance between the front and rear clutch.

You also need to measure the distance between the sides of the front clutch and the sides of the belt but I suspect they are far enough apart not to cause it creeping.

Everything things to be aligned and shimmed properly if you want to enjoy this bike otherwise you will blow belts, have trouble with shifting and possibly leave it in an unsafe condition if it will not idle without it creeping.

 

I wish this quad knew that the rear clutch was supposed to come off easy. It will not let go. I've done the whole pbblaster spraying for 2 days with no luck. I've even tried threading in a 2" ball and pulling. Its really stuck on there.

More and more I'm convinced the motor is out of alignment. I'll probably have to suck it up and order a clutch alignment tool. I needed the driven clutch puller either way. I plan on putting in a clutch kit in the very near future, so the secondary will have to be removed eventually.

 

Thanks for the advice everyone. Don't worry I wont be driving it around in its current condition. I spent 145 w/tax on the new belt and refuse to destroy another due to impatience. I think i will just buy the alignment tool and see what comes from that. The more I think about the problem the more i can see how adjusting the front motor mount can cause all kinds of belt on drive clutch alignments. The advice and suggestions are the exact reason i started the thread in the first place.

 

Not sure if the driven clutch is supposed to float on the shaft as it does on sleds and if it is supposed to and is seized then I suspect that is your main issue as it cannot align itself as the rpm's and ground speed increase.

I always put the same synthetic grease I use on the suspension on the shaft that holds the rear clutch so that is does not stick and runs back and forth freely.

Sounds like you have some major issues that may or may not be resolved with a puller. You may need some heat applied as well but I would talk it up with a dealer and find out the best way to attack the issue. Parts are not cheap and he may only charge you 1/2 hour labor to remove it and that may be well worth the money. He can then put the alignment tool on it to check it and you may have your issue resolved for the price of two pullers.

Just my .02 CDN.

 

Not on the EBS system. Being too tight even if it was guitar string tight will not make it creep.

It is creeping because the belt is not resting center on the one way bearing on the front clutch. It is off to the side rubbing where it should not.

 

Yes. This /\ /\ /\

 

OK does the one way bearing have a lot of side to side play in the clutch?


As I said before many times this is a belt issue. Try reversing the direction of the belt. Does the belt have good consistent deep grooves on the inside. These grooves hold the belt inside the one way bearing.

 

Once you get the secondary off, to align put pachine in nuetral, rev engine to engage clutches, let them spin a while, look at which side the belt is running towrds on the primary and add or remove shims on the secondary to get the belt centered on the primary your right in thinking this can cause your symtoms

 

I got the secondary off and removed one shim, it had two. It no longer creeps in gear. One out of for times it had hard time shifting. I checked the side to side movement on the one way bearing. There was some, maybe a couple mm. How much is normal? I may need a thinner shim on the secondary or the washers on the outside of the one way bearing may have gone bad (or just gone).

Oh and the belt was put on in the right direction, I was able to read it while installing it.

 

Swooshman and I have been discussing this problem on another forum, but I wanted to put my .o2 in here and see if maybe I can get some advice so we can help each other resolve this problem. I also have a 2005 Polaris 800 EFI with the EXACT same problem he is having. I bought this bike used earlier this year, and originally the belt that came on it got wet on teh second ride due to a crack in the clutch cover. So, naturally, while I was riding, chunks of the belt started to come off and eventually the belt slipped off the clutch completely and I had to get towed back to my trailer.

No big deal I replaced the belt with a buddy at his auto body shop. We also repaired the cover and applied gasket maker. Next, a few rides later I began to have issues with the belt creeping and the atv being hard to get in and out of gear. I found a polaris certified mechanic and took the bike to him. He told me the problem with the gear selection is the shift linkage (or something like that) is worn and needs to be replaced. He gave me a brand new belt to try out and see if it helped the creepage. He also told me that if it didn't help out, he may have to remove a shim or two on the secondary clutch to get it aligned, but he said they usually dont go out of alignment like that.

Then he was looking at the primary clutch and he said the inside of it was worn smooth, and that he believed it was supposed to have grooves. He said that he has never seen a smooth clutch like that. He also said there was alot of side to side play in the primary clutch, and that it is not supposed to have that much play.

So I'm hoping someone can offer me some advice and help me save a few hundred bucks on a new clutch and other parts. I have been reading up on this problem and it seems that maybe I should install a clutch kit, being that I have 28" mud tires with rims. I'm wondering if this is putting too much stress on the clutch and causing it to wear out?

Any help or advice is appreciated by swooshman and I. Thank you.