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Setup For My First Sled - 16' 800 Rush LTD

I've finally had a chance to ride a few times but I'm blowing belts before I even get 70 miles on them. I'm not sure what's going on. It's pulling harder than it was before with everything stock but I need to figure this out. In the UP until Sunday and would like to be confident the belt will last. Could the belt is too tight and I need to adjust the secondary? Could it be that the primary is closing too far? Could secondary float cause this? Here is the what I've done with clutching and gearing. Any help would be greatly appreciated.

22 top and 38 tooth bottom gear - 1.73

Indy Specialty Primary Balance and belt indexing
V5-2 Weights - 2 magnets per hole
120-310 Spring
Slick Shift Washer

Team Tied Secondary
Spring 140-220
Helix 66-62F / 68-63F

Gates 46C4387
 
Do indy dans weights have a bushing in them? On his website it looked like no, but wasn't sure what stage of production the picture was taken.

Cg
 
First thing is clutch temp,? What is it, can you keep your hand on them? How are the belts going bad a pic would help, you need float.last shat was the circumference of your belts?
 
Like doc said.

It's very unusual for a Polaris to blow belts??
This can usually get taken care of with belt deflection,alignment and float .
 
cody geyer said:
Do indy dans weights have a bushing in them? On his website it looked like no, but wasn't sure what stage of production the picture was taken.

Cg
Click to expand...
They do not have bushings.
 

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Dr.Notadoo said:
First thing is clutch temp,? What is it, can you keep your hand on them? How are the belts going bad a pic would help, you need float.last shat was the circumference of your belts?
Click to expand...
I was able to keep my hands on the clutches but they were pretty warm. The first belt the outside layer stayed together but inside of the cord it split. The pictures are of the second belt that exploded as I was doing hard pulls on the lake.
 

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Brock said:
Like doc said.

It's very unusual for a Polaris to blow belts??
This can usually get taken care of with belt deflection,alignment and float .
Click to expand...

When I put everything together I set deflection. Alignment and float was set accourding to your thread which was very helpful. I used the aftermarket alignment tool.

I will double check all of these again. I'd like to get my hands on a stock alignment tool to make sure it's aligned correctly.
 
Something is binding .

Can you take primary off?

What is and how many washers behind secondary? Thickness?
 
Brock said:
Something is binding .

Can you take primary off?

What is and how many washers behind secondary? Thickness?
Click to expand...
I left the primary tool at home. I don't recall the thickness of the washers but I left the one thicker and one thinner washer on it. I believe I removed one or two thinner washers from behind.

The deflection was way too tight. Adjusted it and headed to Pat's Yamaha and Polaris dealer to check alignment.

Tapatalk blackmamba
 
Also, what is your engagement rpm and what are the rpms doing throughout the shift? You can use the clutching screen to record speed, rpm and throttle position if you have an IDD. It's nice because you don't have to worry about watching your gauge while you've got a sled to the bar across a lake/field...

Clutch temps should tell you whether the problem is more with your primary or secondary clutch.
 
I pulled the secondary and everything looks good behind there, nothing rubbing. The primary and secondary are the same temp. Compared the temp to a Nytro in the group and they're really close on temp.

I'm hoping they were going because the deflection was too tight.

Tapatalk blackmamba
 
Pats said the alignment and float is perfect. They recommend polaris belts over gates and said I probably got on the throttle too hard before the belt warmed up and created a burn spot. As that spot went around the sheaves it beat up the belt causing it to seperate. So far 70 miles on the new gates belt. We'll see what happens.

Tapatalk blackmamba
 
k5blazer72 said:
Also, what is your engagement rpm and what are the rpms doing throughout the shift? You can use the clutching screen to record speed, rpm and throttle position if you have an IDD. It's nice because you don't have to worry about watching your gauge while you've got a sled to the bar across a lake/field...

Clutch temps should tell you whether the problem is more with your primary or secondary clutch.
Click to expand...
It's engaging at 4150. I can run the clutch diagnostics when I get back by the cabin.

Tapatalk blackmamba
 
Well this belt lasted 108 miles. Broke in it for over 60 miles and let it warm up before getting on it. There was a section of were I hauled for over 20 miles in tight woods. Then a little later I was going down a wide trail that was flat and doing 95 for 10 miles and it let go gassing it out of a corner.



Tapatalk blackmamba
 
New belts need to be washed in warm soapy water and rinsed. Then break in belt easy for 10-30 miles . That means, use an old belt to load on trailer so you don't burn new belt .
 
So my game plan is to check motor mounts and pull both clutches to check everything. Any other suggestions?

Tapatalk blackmamba
 
Your likely problem is your secondary or your belt is too short. You are not overheating the belt based on your checks. Belts fail due to heat or overload. One overload cause is binding in the secondary clutch. One good check is to pull both clutch springs and put the clutches and belt back on. Use your hands to close the primary and open the secondary pushing the belt to follow.

Make sure both clutches are smooth. Make sure you can get your belt slightly beyond the top of the primary. If your checks are good, you only have secondary spring binding left as the cause.
 
I looked at both clutches and they are smooth. After talking to Pat's they really didn't want to look at the clutches until I ran a polaris belt... so I did. I can say the Polaris belt was a lot smoother. The Gates caused a lot of vibrations and when I leaned on the left side while turning and slowing down it felt like the secondary was hitting the side panel. I broke in the polaris belt nice and easy for 35 miles and then did hard pulls. After 30 or more hard pulls from a dead stop and running it hard for 80 miles it hasn't blown yet. I feel the gates would have but time will tell when I go on my next ride. Hopefully soon!

Thanks for the help and feedback.
 
Ru4real said:
Your likely problem is your secondary or your belt is too short. You are not overheating the belt based on your checks. Belts fail due to heat or overload. One overload cause is binding in the secondary clutch. One good check is to pull both clutch springs and put the clutches and belt back on. Use your hands to close the primary and open the secondary pushing the belt to follow.

Make sure both clutches are smooth. Make sure you can get your belt slightly beyond the top of the primary. If your checks are good, you only have secondary spring binding left as the cause.
Click to expand...
This is a very good point. It is possible that your Gates belts were too short as their quality control for length/width has not been the best. Black Mamba, did you measure the "cord length" of any of the belts before you installed them?
 
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