I have a 2003 polaris 4x4 500 scrambler and once i hit 20mph it wont get any higher. Owner claims it went faster and then he blew the belt and after he replaced it the problem started. I've noticed someone has been messing with the wiring up front and put some switches in to run the fan, but he said there wasn't any problems before he blew the belt. Any ideas? thanks.

 

If the belt was just replaced and ramp buttons weren't replaced/checked this could be the problem on speed. Blowing a belt is a good indication that other problems may have happened in the clutches themselves.

 

ok, it sounds like the engine is hitting max rpm, so ill check the ramp buttons. Those are the ones inside the secondary right?

 

Took apart the secondary and there's nothing left of the buttons, plus the clutches are super dirty. So I'll replace the buttons. But I also noticed when I Rev it, the primary torqued towards the secondary a little bit. I'm not sure if that's acceptable or not. Also feels like a little play in between the primary buttons and the walls, how much is acceptable?

 

Check the front motor mount for separation if the drive clutch flexes.Really no play is acceptable on the 6 drive buttons either as all it will do is wear down the clutch spider and make noise over time. Usually when you have to rebuild the rear clutch the front clutch needs attention also. Here's a general repair on a drive clutch. You may not need to remove the button bushings as shown,just the buttons if worn and possibly plain bearings.

 

Ok I replaced the secondary buttons and it goes good now, but I'm wondering if there's a certain measurement I can use to tell if the primary buttons are worn or not. Didn't see anything about button to wall in the manual.

 

There's no set distance in the manual for wear between the buttons and guide towers they ride on. If there's noticeable play when you hold the clutch and twist the spider back and forth,time to replace the guide buttons before they get worse. Just use common sense on this.