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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
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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.
 
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