I have a 2003 Polaris classic 600 touring, need to rebuild the clutch. Where is the best place to get parts and what is the part number. Can anyone help me out on this. Also what brand of belt would you use, I blew a Polaris one out with 500 miles on belt. Thanks
BOTH PRIMARY & SECONDARY
1) Align your clutches (offset, center to center, and check for engine "crooked"), mine and my bud's were off!!!! You may have to shim behind the rear engine bracket(s) to get it perfect. Use thin Chevrolet style starter shims available @ Auto Parts stores under the “HELP” brand.
2) Lightly sand both primary and secondary clutches w/180 grit perpendicular to the way the belt rides and wipe down w/lacquer thinner.
3) Wash/scrub (plastic bristle brush) your BRAND NEW belt w/soap & hot water, and let dry overnight, sounds weird, but it removes the "mold release" compound that would otherwise would get smeared all over your nice clean clutches.
4) If you're blowing belts, clutches/engine is mis-aligned or there are broken motor mounts
PRIMARY CLUTCH:
1) Check your belt to primary sheave side clearance, should be .010" to .015" w/NEW belt, mine was .070" from the factory.
2) Install a new primary clutch spring @ the start of every season. (approx $31.00)
3) Send your primary clutch out to have it balanced. Made a NOTICEABLE improvement in smoothness and extends crankshaft and clutch life, they drilled 8-9 lightening holes in mine, that's how far off it was from the factory!! SLP and others charge only $35.00 for this service. Do this after you've set the belt to sheave clearance.
SECONDARY
Button Secondary
1) Install a new secondary clutch spring @ the start of every season. (approx $31.00)
2) Replace the (3) little plastic wear buttons, they're approx $ 1.00 each