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97 Polaris Sportsman 500 loose drive belt

I have a 97 Polaris Sportsman 500 that has belt drive issues. I have replaced the belt with no success. The belt slips and flops inside the caseing. There is no presence of moisture of debris inside, so the caseing is getting a good seal. Is there a way to adjust the flywheel/expansion cones?

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Hello milez.
The belt as you stated is too loose. This can happen if the belt is worn, improper belt or as I suspect in your case the clutches are worn or sticking.
The primary clutch (on the engine) and the secondary on the transmission.
These two parts must work in unison to operate correctly.
As your engine RPM increases the primary has internal weights which fly out which in turn pushes it together pinching the belt. As it pinches it pushes up the sheaves and pulls the secondary sheaves apart. If the secondary sheaves are stuck apart you will get the condition you are having. You will need to disassemble and clean out this clutch. This can be tricky work as there is a large spring that will unwind when pulled apart. You need to put the proper amount of preload back in during reassembly.
If you want to try to clean it without pulling it apart use some spray brake cleaner and work the sheaves to dislodge any accumulated debris. Then use some lube on the shaft (preferably from your Polaris dealer)
Hope you do OK with it. It's a good practice to learn to do this anyway as you should clean this stuff up yearly.

Posted on Nov 17, 2009

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Posted on Jan 02, 2017

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