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09-11-2012, 10:10 AM
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Polaris ATV Legend
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Member #13240
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,207
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Polaris Xplorer 400 clutch problem...
can someone tell me what is wrong with this thing? the belt goes halfway up the primary then over revs. i put on a different primary and it's the same thing, also replaced the spring and buttons in the secondary.  Any help would be great.
__________________
5140km  2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Modified Stock Muffler, Polaris 3500lb Winch, Rear Rack Extender, Super Atv 2" lift kit, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites!  Maintenance is the key to a never ending happiness
Check out my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
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09-11-2012, 11:52 AM
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Polaris ATV Junkie!
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Member #7218
Join Date: Sep 2010
Location: Winnipeg, Manitoba
Posts: 1,179
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If you have replaced the buttons already,then you have over tightened the spring or tensioned it the wrong way when you put it back together. The sheaves on the secondary should be spreading apart as the primary makes the belt tighter. They are not. It is definately a secondary problem.
On my old 400's you just needed a bit of preload on the spring and my 500HO needed none. Just put it in the holes marked "2"
__________________
2012 Starfire Blue Sportsman 850XPHO LE EPS:
- Fender/ Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, front Lock and Ride box, Uni Air Filter. 27" Black Diamonds Radials, Odyssey Battery
2012 Bronze Mist Sportsman 850XPHO EPS
- Fender/Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad Hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, Front lock and ride box, Uni Air Filter. 27" Black Diamond Radials, Odyssey Battery
2008 Red Sportsman 500HO
-STI Black Diamond radials on STI rims, Kimpex box with seat, Rack/Fender guards w/passenger pegs, Uni Air Filter, HID lights, Ricochet A-Arm guards, Polaris 3500HD, Polaris hand and thumb warmers EPI Front and rear clutch kit.
Faithful friends no longer with me:
94 Sportsman 400 4x4- owned 18 years
2000 Xplorer 400 4x4- owned 10 years
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09-11-2012, 12:10 PM
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Polaris ATV Legend
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Member #13240
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,207
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i can assure you there in the "2" holes, had it apart twice.
__________________
5140km 2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Modified Stock Muffler, Polaris 3500lb Winch, Rear Rack Extender, Super Atv 2" lift kit, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites! Maintenance is the key to a never ending happiness
Check out my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
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09-11-2012, 12:24 PM
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Polaris ATV Junkie!
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Member #7218
Join Date: Sep 2010
Location: Winnipeg, Manitoba
Posts: 1,179
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Did you pretension it before putting back on the snap ring? Can you take your hands and make it open up? If you cant then somthing is either broken or binding.
__________________
2012 Starfire Blue Sportsman 850XPHO LE EPS:
- Fender/ Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, front Lock and Ride box, Uni Air Filter. 27" Black Diamonds Radials, Odyssey Battery
2012 Bronze Mist Sportsman 850XPHO EPS
- Fender/Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad Hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, Front lock and ride box, Uni Air Filter. 27" Black Diamond Radials, Odyssey Battery
2008 Red Sportsman 500HO
-STI Black Diamond radials on STI rims, Kimpex box with seat, Rack/Fender guards w/passenger pegs, Uni Air Filter, HID lights, Ricochet A-Arm guards, Polaris 3500HD, Polaris hand and thumb warmers EPI Front and rear clutch kit.
Faithful friends no longer with me:
94 Sportsman 400 4x4- owned 18 years
2000 Xplorer 400 4x4- owned 10 years
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09-11-2012, 01:39 PM
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Polaris ATV Junkie!
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Member #14887
Join Date: May 2011
Location: NB. Canada
Posts: 642
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Was it doing the same thing it is now ,before you changed the secondary spring and buttons? Maybe you installed a stronger spring than you're supposed to?
I believe it's the secondary clutch as well.
To rule out the primary though, take off the belt and rev the engine up and down. Does the primary clutch move in and out at least an inch? If it does , then it's probably OK....
You will have to investigate the secondary some more. Like the previous poster said, you should be able to push the inner sheave in with your hands. If you can't , then the belt can't....
If you disassemble the secondary and the sheave moves up and down freely , then it's probably a spring tension issue.
Great video by the way!!
Kevin
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09-11-2012, 03:40 PM
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Polaris ATV Legend
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Member #13240
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,207
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it messed up earlier, then we put the new parts in the secondary, it was fine for probably 4 months now it does this. primary fully closes with the belt off. guess i will explore the secondary further.
__________________
5140km 2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Modified Stock Muffler, Polaris 3500lb Winch, Rear Rack Extender, Super Atv 2" lift kit, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites! Maintenance is the key to a never ending happiness
Check out my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
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09-11-2012, 04:43 PM
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Polaris ATV Junkie!
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Member #7218
Join Date: Sep 2010
Location: Winnipeg, Manitoba
Posts: 1,179
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Well if it worked for a while and then stopped after you fixed it, then open it up and see whats going on inside. Maybe a screw came out of one of the buttons or???? It is definately in the secondary.
__________________
2012 Starfire Blue Sportsman 850XPHO LE EPS:
- Fender/ Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, front Lock and Ride box, Uni Air Filter. 27" Black Diamonds Radials, Odyssey Battery
2012 Bronze Mist Sportsman 850XPHO EPS
- Fender/Rack guards, 3500lb PolarisHD winch, Polaris hand and thumb warmers, Powermad Hand guards, HID lights, ATV Guru Front Guard, Ricochet A-Arm guards, Front lock and ride box, Uni Air Filter. 27" Black Diamond Radials, Odyssey Battery
2008 Red Sportsman 500HO
-STI Black Diamond radials on STI rims, Kimpex box with seat, Rack/Fender guards w/passenger pegs, Uni Air Filter, HID lights, Ricochet A-Arm guards, Polaris 3500HD, Polaris hand and thumb warmers EPI Front and rear clutch kit.
Faithful friends no longer with me:
94 Sportsman 400 4x4- owned 18 years
2000 Xplorer 400 4x4- owned 10 years
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09-12-2012, 12:10 AM
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Polaris ATV Legend
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Member #13240
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,207
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i took it apart again once this happened, didn't see anything wrong, will look again.
__________________
5140km 2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Modified Stock Muffler, Polaris 3500lb Winch, Rear Rack Extender, Super Atv 2" lift kit, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites! Maintenance is the key to a never ending happiness
Check out my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
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09-12-2012, 12:21 AM
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Polaris ATV Legend
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Member #13240
Join Date: Mar 2011
Location: Renfrew, Ontario, Canada
Posts: 2,207
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wish i could find a used secondary, save me messing with this one anymore.
__________________
5140km 2008 Polaris Sportsman 500 Ho, Polaris Hand & Thumb warmers, RotoPax 4 Gallon Fuel Pack, Custom Made Rear Bumper, PowerMadd Hand Guards, Polaris Rear Work Lights, Ricochet Ultimate Armor, Modified Stock Muffler, Polaris 3500lb Winch, Rear Rack Extender, Super Atv 2" lift kit, Polaris Brush Guard, 3 Headlight Mod, Uni Air Filter, EPI 'patv1' primary clutch spring. All up on Interco Swamplites! Maintenance is the key to a never ending happiness
Check out my youtube channel! ---> http://www.youtube.com/user/mudsling...ew=0&flow=grid
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09-12-2012, 07:16 AM
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Polaris ATV Junkie!
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Member #14887
Join Date: May 2011
Location: NB. Canada
Posts: 642
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There's very little going on inside the secondary clutch assembly. I wonder what the problem would be?
Do you still have the old spring? Did you change it because it was broken? Can you bring your secondary assembly to an ATV shop for someone to look at?
__________________
Kevin
2001 Sportsman 500 HO
Famous saying......" I'm going to the garage" !
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