Well, as luck would not have it, a neighbor jumped on my 2001 xpedition and took off with the parking break locked down hard. He had the motor pegged and it was only going about 3 MPH but for some odd reason he thought hammering down on the shifter might fix the problem. By the time I got him stopped the clutch area was too hot to touch and now when I try to put it in gear it will grind a little, lerch and kill the motor, sometimes just spin and grind.. Anyone have an idea where to start and / or what I am looking for once inside?

Note, this is a 4 stroke shaft drive model.


Thanks All
jc

 

Other than saying keep your neighbor off the machine(or any other mechanized vehicle) which is too late,I'd check into the centrifugal clutch pack as well as the clutch plates since this system has both! Sounds like he's glazed,burnt up the clutches causing them to stick. Can be expensive! No better way to ruin family and neighbor relationships than on borrowed machines. I've seen this happen often..http://www.cyclepartswarehouse.com/f...2001&fveh=5567

 

First thing fist is take off the belt cover and see what up in there.
Not sure what you mean by hammer the shifter down? Forward is forward pressing the shifter more forward will not give him more forward.
Or did he put it in forward while the motor was at high rpm?

Opps I thought the ATV was a automatic not a 5 speed.

 

This is not a belt drive system! It's an automatic wet clutch 5 speed similar to Honda,etc and a pain to work on because of all the parts involved.Holds 5 1/2 quarts of oil!

 

I pulled the housing off and can feel grit on the outside of the centrifugal clutch. ( the housing part ). When I turn it manually, it looks like its a little out of round by maybe a 1/16 of and inch. Can these be rebuilt or turned or am I stuck buying a whole new unit.

Second, when its in gear it seems fine until you get off the gas a little and then it kinda of grinds / catches.

Is there a way to check the clutch plates without taking the whole assembly apart. From the looks of it, I might be getting in over my head.

 

You can replace the clutch pack item#23 but not through Cycle Parts warehouse evidently.Probably only through Polaris dealers.
As long as the drum isn't warped from heat it can be reused. The other clutch plates hopefully haven't been over heated as the centrifugal clutch will usually take the brunt of the damage.

 

Thanks for your help OPT.
Here is a pic, the part on the left is what seems out of round by about 1/16 of an inch. Should I start by just replacing the housing or should I purchase the whole assembly. Do you know how I can check the other parts.

I cleaned it up and am going to bolt it back together, fill it with oil and see how it acts. When I do this, is there anything I should pay attention to that will identify any other parts I might need?

 

If it's grabbing and sticking I wouldn't just waste 5 quarts of oil. I'd take the left centrifugal clutch off and check it out,then you have room to check out the clutch plates on the other motorcycle type clutch. Could be a just taking a light emery cloth paper to everything, drum,clutch plates,etc and clean up with brake cleaner and reoil may solve the problem. The idiot neighbor may have just "boiled the oil" when the brake was locked and glazed/gummed the clutches up causing them not to release. At least worth a try.

 

This has to be the easiest fix to me . Give the Dealer your neighbors address so they know where to send the bill.

I jumped on my dads ATV and rolled it down a large hill end over end and lost count of how many endos. , It was $1300 of damage once it settled down at the bottom of the hill.
Cost my dad $0 cost me $1300.
He did not even let me work on it,he just dropped the ATV at the dealers and I had to pick up the ATV and bill.LOL

 

This is the best way if he could get his neighbor to foot the bill,but again he has to live next to this guy too! Plus TLC your dad could have told you to keep your butt off his machines and stopped it before it happened!!! A good neighbor (you can find out quick if they are or not) would normally offer to pay for any damage incurred if it does has to have to put in the shop. I've laughed about this for years when machines were brought into the shop with damage from kids,brother in laws,neighbors,friends,etc. Had one Sportsman brought in with a bent a arm and rim that the owners neighbor damaged and returned it back into the barn and never said a word! They HAD been friends for 25 years,but it ended that day!...