03 xc 700sp sticking clutch

[moosehunter]

When cold starting the machine and then spinning out the track the driven clutch is not releasing the belt and backshifting. When it idles down then it will stall out because it is in the wrong gear. Then to start it I have to pull the belt back to the top before I can start the machine again. This also seems to happen when everything is hot and travelling on a slower trail. I have tried to clean the clutch but it doesnt seem to help. I'm not sure if it would help to change the spring. Right now everything is stock.

Has anyone out there had similar problems or heard of a fix for me? I'm starting to get desperate here.

[geegsxcsp]

I had this happen to me a few years ago and I tore everything apart and rebuilt both clutches only to have the same problem exist until my friend said take the secondary clutch off and clean up the shaft with emery cloth and oil it lightly. I did that and It worked like it was supposed to from there on out. Hope this helps!

[revrider19]

its possible that the thing just plain needs rebuilt a bad bushing will "cock" the sheaves and you may not be able to "see" the problem when torn apart . and you may not be able to "wobble" the sheaves by hand . take it to a good clutching expert and have them look at it . if it was mine id take the primary and secondary . have them rebuilt and possibly "reclutched for a better clutching set-up. my opinion.

[moosehunter]

The damn thing still sticks!

I cleaned everything up including cleaning the shaft with emery cloth. When I put it back on and started the machine on the stand the clutch did the same old thing. I let the machine warm up and then spun the track a bit. When I let it idle down the track continues to spin because the belt is not coming back to the top of the secondary clutch. If I apply the brake the machine stalls out and I have to physically pull the belt to the top so that I can restart the machine.
This has happened pretty much since day one and I have talked to 2 other people that have similar problems. I would like to try different clutching setups but the problem is finding someone in my area that knows what they are doing. I dont really like to take it to the dealer, havent had much luck there in the past with this problem and/or others.

Can I change the bushing myself in case it is having a "cocking" issue?

[Sleddin Capital of Can.]

In my expert opinion i would say there is only three reasons for your clutch to be performing like this. First the sled is probably carrying too much weight. Have you put on a few extra say 100 pounds since you purchased the sled? Might be time to loose some of that. Second, have you ever been cocky and tried to cross open water with a minimal starting distance and ended up sinking your sled in 20 feet of water. If yes, your redneck and your sled will never be the same. Finally for the third reason i would have to say is lack of use. Do you find yourself just looking at your sled most weekends instead of riding it. If yes you might as well sell the sled, buy a mountain sled and move to Alberta Canada. If you are not willing to move i would say your best option is to burn the 700 and buy yourself a black and silver 04 Polaris 500. This is one of the best sleds Polaris has produced, you will not have any problems with it and it will out perform your 700 in all categories.

[moosehunter]

Sounds like a good sled for my wife!

You sound like a Weasel I know

[m_scott]

is the belt the right size?? and is the clutch adjusted right. not sure how to adjust the clutch so i would say check your belt to see if its the correct size.

Your spring could be weak and possibly your wieghts are sticking. Do a complet clutch rebuild and see what it does for ya..

and if you sink your sled it has no effect on the sled if you properly take care of it. once you get it out of the watter get it running asap. then run it for an hour and park it in a heated garage with all drain plugs out. I have evene seen a sled that has been left in a lake for a year pulled out cleaned up and ran perfectly. all they did to it was steam clean everything drain everything then put new gas in and started on the 4th pull. AFTER BEING IN THE BOTTOM OF A LAKE FOR A YEAR.

[moosehunter]

Dont worry, thats just my buddy tryin to get under my skin! I did sink my sled 2 years ago though. We had it out the same day and I drained and cleaned everything back in a heated garage. It has run without any problems ever since. The worst thing was trying to dry the seat out. I finally had to take the cover off it and leave it next to a fire for two weeks.

As for the clutching, it is the OEM recommended belt and when I originally started haveing the problem and took it to the dealer they checked for alignment.

[m_scott]

the numbers may match but the belt might just be worn out. doesnt hurt to grab a new belt and put it on to see what happens.

[moosehunter]

Thanks,
I will give it a try. I have a new belt sittin at home but was waiting to fix the problem before putting it on. I didnt want to waste the new belt because they aint cheap, but maybe it is part of the problem.

[revrider19]

dont skimp on your belt
buy a good one
ultimax3 ?

spend more now not later

[PolarisXC800SP]

My buddy had an 01 XC600SP and he had the stalling problems and sticky clutch with his sled 2 years ago. The clutch was done and needed to be replaced. The only way we were able to get it going to get us back, is use a hammer or axe to give a little tap on the side of the clutch. All the of the parts at the side were worn and had metal shavings all over the clutch.

[moosehunter]

Just to give anyone who cares an update.

As I mentioned I knew another sled having the same problems. He took his sled to the dealer and made them look into things, explaining that mine was doing the same and what I have tried to fix. I have been blaming the secondary the whole time, however the dealer started looking at the primary. They ended up taking the primary apart and sending it to a machine shop where they machined the shaft, similar to a sanding. By the time he got the sled back there wasn't much snow left but he was able to take her out for a quick boot. It seems to be fixed but we will soon get a better idea when there is some snow up here for riding. Dealer couldn't explain why it would have to be machined but said maybe it was overheating or extra dirt build up.
I'm planning on trying this on my sled before going out this year and will keep everyone posted.
Thanks for the help.