1998 Polaris Xplorer 400 Secondary Driven Clutch Installation

[dawgkllr]

I replaced the starter on my ATV and had to remove the secondary driven clutch assembly to remove a couple of the bolts. The unit came off easily but now I cant get it to slide all the way down the shaft to engage the spines on the shaft so that I can bolt it back up. What am I doing wrong? Is there a "trick" to it or a tool that is needed?

[marioweldinginc]

Yea its called a Honda

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[oxidized_black]

Yea its called a Honda

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OUCH !!! :explode2:

[CK1999_400ex]

thoes can be hard 2 put on... you might have to get a longer bolt and tighten it very slowly to get it to go down to the splines... but you have to be very careful doing it or you can damage the shaft an threds an the splines ... use some lube also...

[marioweldinginc]

Or just get a Honda

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[JamesBond007]

i think mario has had 2 many polaris 4x4's have to pull him out of the mudholes lol

[marioweldinginc]

Not a chance.. More like my 400ex pulling out polaris 4x4s

Remember friends dont let friends ride polaris

Actually i could care less as long as your out there riding and enjoying your atv it could be a 200 dingdong motors quad and id still respect you in the morning :thumbup:

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[swampcat07]

I replaced the starter on my ATV and had to remove the secondary driven clutch assembly to remove a couple of the bolts. The unit came off easily but now I cant get it to slide all the way down the shaft to engage the spines on the shaft so that I can bolt it back up. What am I doing wrong? Is there a "trick" to it or a tool that is needed?

Don't be shy when putting it back on keep rotating the clutch and pushing it on. When the splines line up it should go about 3/4 of the way on then just make sure you use an impact and the proper torque to make sure you have it on all the way. Also use red loctite on the nut, I have seen some of the clutch nuts work their way free on other bikes. I am working on my clutch today changing over to a winter belt for plowing, I'll take some pics.

[dawgkllr]

Thanx for the info swampcat07. Headed to the hardware store now to get a longer bolt.

marioweldinginc please get off of your mommy and daddys computer and go back to playing with your hot wheels and power rangers. When your parents find out youve been playing on grown up sites again they're gonna block your online fan membership to Hanna Montana.

[oxidized_black]

thanx for the info swampcat07. Headed to the hardware store now to get a longer bolt.

Marioweldinginc please get off of your mommy and daddys computer and go back to playing with your hot wheels and power rangers. When your parents find out youve been playing on grown up sites again they're gonna block your online fan membership to hanna montana.

[rappy97]

Dawg... Keep up the good work.

[dawgkllr]

Don't be shy when putting it back on keep rotating the clutch and pushing it on. When the splines line up it should go about 3/4 of the way on then just make sure you use an impact and the proper torque to make sure you have it on all the way. Also use red loctite on the nut, I have seen some of the clutch nuts work their way free on other bikes. I am working on my clutch today changing over to a winter belt for plowing, I'll take some pics.

Swampcat07 using the longer bolt worked like a charm! Now that its all back together it runs like a scalded ape forward but bogs down in reverse. Any suggestions!

[oxidized_black]

now you can celebrate riding into the new year!!! good job guys!!! :partyc:

[dawgkllr]

Thank ya oxidized_black and thank you for keeping me straight on who gave me the tip about using the longer bolt. Thank ya ck1999!

[CK1999_400ex]

no prob man.... glad it worked out for ya .... as for your reverse issue ... is the rev limiter causing it 2 do that in reverse?

[dawgkllr]

I will check that in the morning but I am betting that is going to be the issue.

[marioweldinginc]

Thanx for the info swampcat07. Headed to the hardware store now to get a longer bolt.

marioweldinginc please get off of your mommy and daddys computer and go back to playing with your hot wheels and power rangers. When your parents find out youve been playing on grown up sites again they're gonna block your online fan membership to Hanna Montana.

My hot wheels will still have to winch out your polaris sir

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[dawgkllr]

Well if I gotta get wenched out then I can't think of a better pulling unit than a Hot Wheels! I appreciate you being there for me mario!

[marioweldinginc]

Ten 4 good buddy hope your atv is back up and running

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[oxidized_black]

wow... i cannot believe this thread. a new member looking for help with his quad and all hell breaks loose with another member. my god, the drama.... tsk tsk

not a good way to start the new year

Edited January 3, 2012 by oxidized_black

[marioweldinginc]

Oxy we are onto another subject keep up!

:D:D

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[oxidized_black]

Oxy we are onto another subject keep up!

:D:D

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keep up or grow up?

dead link

Edited January 3, 2012 by oxidized_black

[swampcat07]

Swampcat07 using the longer bolt worked like a charm! Now that its all back together it runs like a scalded ape forward but bogs down in reverse. Any suggestions!

No problem I know the AC clutches are not exactly the same so it sounds like the longer bolt is the fix. My quad has a reverse rev limiter, maybe its that. I can overide it by having it in 4WD and pushing an overide button. I almost flipped it when I did that though. Does it sound detuned/missing when WOT in reverse?

[rappy97]

Lol at this thread.

[dawgkllr]

Swampcat that's it exactly..... Sounds and runs like heck in reverse. I'm pretty sure it's going to be the reverse limiter and will confirm in the morning and post my findings.

[dawgkllr]

Oxidized black. It's ok my ride is fixed and my frustration level is now lower so pokin back at mario is kinda humorous. (I guess I should tell him about having to pull a buddy's Honda Rancher across a mud hole because the weight of my buddy and a 225 pound hog on the Rancher was just to much for the Honda ). I appreciate the backup!!! Y'all all have a good evening!

[rappy97]

Give Mario another chance.... He's just special, he can't help it.

[cheriah]

Mario has a temporary allergic reaction to latex and that is why he acts this way sometimes......his eyes bug out of his head and he foams at the mouth also during this time...don't take it personally,,,,he's just Mario and we luv him that way:laugh:

[marioweldinginc]

Thanks ... I guess

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[marioweldinginc]

Oxidized black. It's ok my ride is fixed and my frustration level is now lower so pokin back at mario is kinda humorous. (I guess I should tell him about having to pull a buddy's Honda Rancher across a mud hole because the weight of my buddy and a 225 pound hog on the Rancher was just to much for the Honda ). I appreciate the backup!!! Y'all all have a good evening!

So was there a Honda pulling the Polaris pulling Honda giggity

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