Broke down -need opinions

L

lazer103

Member
I have a 2004 polaris xc 800. 5800 miles. On sat i was riding and heard some squels every so often. Not loud. I put a new polaris belt on about 300 miles ago. Next day was riding and lost power. Could only go about 15mph. Engine runs fine. While limping home lost total power. Then after i was stopped i gave it gas and then i could only go about 15 mph. Again. Went a little ways then sled slowed to a stop. I repeated this process of going for 17 miles !!!!! I checked the belt, looked great. No wear or damage but sure felt hot.

So..... Whats the problem ???? Any ideas.. Regardless i bet i am in for a big bucks repair
 
J

jccams

New member
Did you set the belt deflection when you replaced it? Squealing and hot belt both sound to me like the belt is too tight. Not sure about the loosing power and 15mph though.
 
D

Dave_B

Active member
Not an expert but, my guess is a secondary clutch issue. I've but new belts on and had the squeeling niose and had to adjust them on the secondary but, if you put 300 miles on it, that's probably not it.
 
D

Dave_B

Active member
jccams said:
Did you set the belt deflection when you replaced it? Squealing and hot belt both sound to me like the belt is too tight. Not sure about the loosing power and 15mph though.
Click to expand...

Belt is for sure too tight if it's hot. Are you sure it's the right belt?
Stupid question but I had a friend put the wrong belt on (not intentionally) and he had the exact same problems you are having. No power and 15mph max.
 
W

whitedust

Well-known member
Dave_B said:
Belt is for sure too tight if it's hot. Are you sure it's the right belt?
Stupid question but I had a friend put the wrong belt on (not intentionally) and he had the exact same problems you are having. No power and 15mph max.
Click to expand...

X2 Wrong belts happen more than you think check it out happned to me on old poo.
 
L

lazer103

Member
Hi all, thanks for your thoughts... I did put on the correct belt... I bought it from a polaris dealer and the numbers matched... I also put in on correctly with the numbers facing oout toward me.... I thoguht it may be to tight so i used that allen wrench to loosen up the belt... I sure did loosen it.... Flops around like a fish out of water... Problem now i have no idea how to tighten it back up !! If i pull plugs, what am i really looking for. Black burn marks on piston ??
 
E

ezra

Well-known member
white plugs is not a good sign chunks of alloy on plugs not good.
I am also going with broken spring or shot buttons on clutch.
is sled still running ok?
or is sled actually stopping running?
if sled is still running prob a clutching issue
or worse case crank bearing but more likely clutch both need rebuilding.
 
V

vic_junior

Member
You stated the engine runs fine. Do a quick check of the plugs and compression if you can. Sounds like the primary needs to be rebuilt.
 
L

lazer103

Member
The sled / engine runs fine... It just goes 15mph for a short ways and then slowly comes to a stop. I let off the throttle then when i hit the throttle i heard some clunk noise then i take off going and some time get up to 25, but then the sled slows down but engine rpm stays up there until i back off throttle
 
E

ezra

Well-known member
then deff clutches.
broken springs
wore out buttons
auged out weights
or all of the above and more
prob busted spring
 
M

motor_slut

New member
possible problems
-Bushing on the Team secondary went bad and jammed up the clutch (replace helix)
- Weights are going sideways jamming primary clutch (replace weights/pins)
- bushings in primary clutch bad (replace)
-brake stuck on

A broken clutch spring is not likely as it would go faster than 25mph. A bearing will not slow the sled down so chances are good it's not a drive bearing. It's worth checking these but not likely the cause of your problem.
 
You must log in or register to reply here.
Top