04 Sportsman 500. About 2 years ago I replaced the orig. drive belt it was toast due to towing a few heavy loads and the beatings from the kids. Today I tore up a belt just riding but there is just one spot on the belt that looks like cr@p the rest of it looks fine. I don't know alot about the clutches but when running it with the cover off the primary runs way in (I think) compared to an idle. So is this normal and the belt just was done or am I looking at a clutch problem? when I replaced the belt last time I used an OEM. Any thoughts will help. Thanks.

 

at idle your primary clutch will be open and once the engine is reved up the primary will close to squeeze the belt while the secondary clutch will open up. when they are doing this they are causing pressure on the belt for movement(no slippage) off the bike. check the faces on the clutch(while engine turned of course) for any rough spots or marks that could have hurt the belt. it's always good to stick with the oem polaris belt.

 

Sounds to me like the belt did a "BURN IN" if it is only bad in one spot.
The primary was pulling in but the secondary(Polaris calls driven clutch) was not moving.
You may have a issue with the "RAMP BUTTONS" on the secondary or spring issue.

The one spot that you talked about.....is it burned in like a half moon? or top ribbed cords comming off? or side cords hanging out?
........Caper...............

 

Caper thanks I will check on Tuesday I just got done with a 24 hour shift and I need to be in by 7 am but I will check.