[Calirubicon]

Hi there. New to the forum but have ridden Polaris for years. But now I have an issue that I can't find the answer to. 2005 800efi. Starts fine, no abnormal sounds, shifts fine then when I give it throttle it won't move at all until I'm almost topped out and then it only moves about 2mph. Belt? Clutch? Any ideas on where to start would be appreciated. I'm quite a distance from any service places so I'm hoping to get this fixed myself. Thanks for your time.

 

[denseleit]

Belt fried or clutch seized.

 

[Calirubicon]

Thanks for the quick reply. Any way to tell before I open it so I can get parts ordered? Also from what I read the belt does not look like a bad job to do. How hard is the clutch to replace? Thanks again.

 

[denseleit]

No way to tell with out pulling off belt cover.

 

[bgirard420]

:dito:
Got to open it up and take a look. Changing belts is a novice level repair, but changing clutch parts can become expert level quickly depending on what is worn/broken. If you're unsure about anything, be sure and post up or go to the stealership.

 

[Calirubicon]

Thanks for the advise. Got an oem belt ordered. Found new on eBay for half the price. Thanks again. Good riding.

 

[Calirubicon]

Ok so I've got my new belt and want to tackle this job tomorrow. Been on utube and google and I can't seem to find any good walkthroughs. If anyone has any advise or links that would be great. Thanks.

 

[blueline15]

How much freeplay is in the throttle lever before it starts increasing the RPMs when you press on it?

 

[bgirard420]

There is a four part video series on installing a clutch kit. Not all parts will pertain but there are some spots that do like dressing the sheaves and reinstalling the belt. It's important to get all the old belt dust out and everything squeeky clean again

My secondary isn't the same as the one in the video, I have to rotate both secondary sheaves in opposite directions to open up the secondary, there is no tool or screwdrivers for the 2010's. I am unsure what the 05 is like :thinking: but I am sure it can't be too different. Also, be sure and wash the new belt in some mild soap solution and let it dry before installing.

 

[denseleit]

Here's another one..

 

[Calirubicon]

Seems like throttle is fine it just takes a high rpm to get it to move.

 

[Calirubicon]

Thanks for the vids. I'm going to give it a try tomorrow.