Polaris ATV Forum banner
1 - 12 of 12 Posts

·
Registered
Joined
·
4 Posts
Discussion Starter · #1 ·
Hey so I just joined here cause I need help. I just got my first atv, a 2002 sportsman 400 but haven't been able to use it yet. When I picked it up it wouldn't go over like 20mph. After doing research I found that I should rebuild the secondary clutch, buttons, check helix, belt, resurface sheaves, and adjust with shims for the new belt, and I've done all that. I'm new to atvs, but very use to working on cars and motorcycles. Anyways. I put everything back together per how I disassembled it but also following the manual and youtube videos, and have taken it apart and back together like 4x now, and feel confident everything is as it should be. In neutral everything seems good. If I put it in reverse it starts to back up on its own with no throttle, which isn't right. And if I put it in high the secondary clutch goes completely open, belt drops all the way down, and if I give it gas, the primary spins and closes but the secondary stays completely open....so the belt just flops around and I don't move. The spring is not broken, sheaves are clean, new buttons. New belt, spring is in hole #2 on clutch and helix, clutches are aligned.......I don't know what to do! I've been researching like crazy and can't figure it out. Please help. First 2 pics show what it does when I put it into gear
Tire Wheel Automotive tire Locking hubs Automotive lighting

Tire Automotive tire Tread Synthetic rubber Automotive lighting

Wheel Tire Vehicle Automotive tire Tread
 

·
Premium Member
2008 800 ho efi, 2019 850 SP premium
Joined
·
14,063 Posts
Welcome to the forum
 

·
Super Moderator
Joined
·
15,874 Posts
Each time I take it off I can see the spring still seated in the helix, and then when I pop the helix out I can see it's still seated in the clutch. Hmm..
Hmm for me too lol.
I'll have to think about that one. It's been a while since I've had one of those older secondary clutches apart. It should take a lot of effort to pry the sheaves open. Even then they'll snap right back together when released.
Are you getting the moveable sheave and helix pushed all the way down and seated completely down in place? Also there is a spline boss on the shaft and helix that must be aligned correctly. Bearings in the movable sheave and splines in the helix and shaft in good shape? Spacer under the snap ring?
Can you pull the clutch open with your hands when assembled?
I'm just throwing things out there.

I think I've got an old one at the shop that I may take apart this evening just to see if I can figure out what your problem is... You've got me curious now lol.
Bird Cartoon Beak Vision care Iris


Let us know if you find something.
 

·
Registered
Joined
·
4 Posts
Discussion Starter · #10 ·
Thank you everyone for your replies. Polman500, when it's off the bike, it's tight and if I move the movable sheave it snaps back like it should. It's only once on the bike and I put it in gear that it opens up super loose. Could engine mounts shifting cause this, or shifting linkage? Just throwing out ideas too. I do believe that the sheaves and helix and spring are seated correctly, and they are down all the way, but if they weren't...I wouldn't be able to get the snap ring on right? The boss spline and notch in the helix are lined up and marked. I do have the washer that goes under the snap ring. The bearing are JUST starting to show copper, like just a speck, so I know those will need to be changed at some point, but I think their ok for now, and shouldn't affect this. The splines on helix and shaft look ok. And no I can't pull the sheaves apart when assembled. I can rotate them and they snap back, but that's it. Also, I had all 4 wheels in the air, and without even turning it on, if I put it in gear from neutral it opens up and makes the belt loose.
 

·
Super Moderator
Joined
·
15,874 Posts
Sounds like you have everything right. I'm stumped for now. Maybe someone else has an idea of what's going on?
Don't think mounts could affect it that way.
I think you said you installed a new belt... What brand/number? Should be 3211077 or equivalent.
 
1 - 12 of 12 Posts
Top