’98 Xpress 300 won’t go forward after clutch removal
Hi,
Last year my son received a 98 Xpress 300 as a gift from his uncle. It worked fine, except the starter didn't work and it grinds in reverse. Reverse isn't important, but he purchased a starter and we just finished putting it in. We had a lot of trouble getting the secondary clutch off (I bought pullers for both clutches) but it finally popped off after shortening the puller and filling the hole with grease. It was tight enough that the puller actually flattened a bit on the end of the spindle. In an effort to get the puller out, we actually took the clutch apart to potentially heat the shaft, but ended up getting it out with a BIG impact gun. We put the secondary back together on the 2-1 setting and put it all back together. Without realizing it, when we were first working to pull the secondary we had it in gear. Once we realized it we put it in neutral and blocked the secondary. It was substantially harder to get off than any clutch I've ever pulled from a snowmobile... It was my first time pulling one on an ATV.
Now the problem we have is it doesn't seem to engage in forward gear. When we put it in reverse, it stops the secondary when it engages (as I would expect) and still grinds when going backwards, though not quite as bad as before. When we put it in forward the secondary just continues to spin with virtually no resistance. I can see the primary engage and pull the belt into the secondary, but it does not seem to engage the gears. If we push the lever forward we do hear some clicking. It's almost as if it is out of alignment, but having never worked on the gearboxes I thought I'd ask for advice before I started adjusting anything.
With how hard we had to turn the puller to get the secondary off, could we have bent or caused something to be misaligned? The boy is really disappointed right now and itching to keep working on it, but I really wasn't sure where to go next. Any advice would be appreciated.
Thanks
Will
Last year my son received a 98 Xpress 300 as a gift from his uncle. It worked fine, except the starter didn't work and it grinds in reverse. Reverse isn't important, but he purchased a starter and we just finished putting it in. We had a lot of trouble getting the secondary clutch off (I bought pullers for both clutches) but it finally popped off after shortening the puller and filling the hole with grease. It was tight enough that the puller actually flattened a bit on the end of the spindle. In an effort to get the puller out, we actually took the clutch apart to potentially heat the shaft, but ended up getting it out with a BIG impact gun. We put the secondary back together on the 2-1 setting and put it all back together. Without realizing it, when we were first working to pull the secondary we had it in gear. Once we realized it we put it in neutral and blocked the secondary. It was substantially harder to get off than any clutch I've ever pulled from a snowmobile... It was my first time pulling one on an ATV.
Now the problem we have is it doesn't seem to engage in forward gear. When we put it in reverse, it stops the secondary when it engages (as I would expect) and still grinds when going backwards, though not quite as bad as before. When we put it in forward the secondary just continues to spin with virtually no resistance. I can see the primary engage and pull the belt into the secondary, but it does not seem to engage the gears. If we push the lever forward we do hear some clicking. It's almost as if it is out of alignment, but having never worked on the gearboxes I thought I'd ask for advice before I started adjusting anything.
With how hard we had to turn the puller to get the secondary off, could we have bent or caused something to be misaligned? The boy is really disappointed right now and itching to keep working on it, but I really wasn't sure where to go next. Any advice would be appreciated.
Thanks
Will
’98 Xpress 300 won’t go forward after clutch removal
Hi,
Last year my son received a 98 Xpress 300 as a gift from his uncle. It worked fine, except the starter didn't work and it grinds in reverse. Reverse isn't important, but he purchased a starter and we just finished putting it in. We had a lot of trouble getting the secondary clutch off (I bought pullers for both clutches) but it finally popped off after shortening the puller and filling the hole with grease. It was tight enough that the puller actually flattened a bit on the end of the spindle. In an effort to get the puller out, we actually took the clutch apart to potentially heat the shaft, but ended up getting it out with a BIG impact gun. We put the secondary back together on the 2-1 setting and put it all back together. Without realizing it, when we were first working to pull the secondary we had it in gear. Once we realized it we put it in neutral and blocked the secondary. It was substantially harder to get off than any clutch I've ever pulled from a snowmobile... It was my first time pulling one on an ATV.
Now the problem we have is it doesn't seem to engage in forward gear. When we put it in reverse, it stops the secondary when it engages (as I would expect) and still grinds when going backwards, though not quite as bad as before. When we put it in forward the secondary just continues to spin with virtually no resistance. I can see the primary engage and pull the belt into the secondary, but it does not seem to engage the gears. If we push the lever forward we do hear some clicking. It's almost as if it is out of alignment, but having never worked on the gearboxes I thought I'd ask for advice before I started adjusting anything.
With how hard we had to turn the puller to get the secondary off, could we have bent or caused something to be misaligned? The boy is really disappointed right now and itching to keep working on it, but I really wasn't sure where to go next. Any advice would be appreciated.
Thanks
Will
Last year my son received a 98 Xpress 300 as a gift from his uncle. It worked fine, except the starter didn't work and it grinds in reverse. Reverse isn't important, but he purchased a starter and we just finished putting it in. We had a lot of trouble getting the secondary clutch off (I bought pullers for both clutches) but it finally popped off after shortening the puller and filling the hole with grease. It was tight enough that the puller actually flattened a bit on the end of the spindle. In an effort to get the puller out, we actually took the clutch apart to potentially heat the shaft, but ended up getting it out with a BIG impact gun. We put the secondary back together on the 2-1 setting and put it all back together. Without realizing it, when we were first working to pull the secondary we had it in gear. Once we realized it we put it in neutral and blocked the secondary. It was substantially harder to get off than any clutch I've ever pulled from a snowmobile... It was my first time pulling one on an ATV.
Now the problem we have is it doesn't seem to engage in forward gear. When we put it in reverse, it stops the secondary when it engages (as I would expect) and still grinds when going backwards, though not quite as bad as before. When we put it in forward the secondary just continues to spin with virtually no resistance. I can see the primary engage and pull the belt into the secondary, but it does not seem to engage the gears. If we push the lever forward we do hear some clicking. It's almost as if it is out of alignment, but having never worked on the gearboxes I thought I'd ask for advice before I started adjusting anything.
With how hard we had to turn the puller to get the secondary off, could we have bent or caused something to be misaligned? The boy is really disappointed right now and itching to keep working on it, but I really wasn't sure where to go next. Any advice would be appreciated.
Thanks
Will
2001 sportsman 90 alternative gearcase oil?
Is there another gear case oil that I can use besides the Polaris oil that is mentioned in the manual?
Did the Factory ever produce a locked up OEM clutch?
Im curious has the factory ever fixed the primary clutch slip issue? I see a primary for sale labeled as OEM but it has the ring and front rivets identical to the primaries that have the locked up mod on them.
just curious! thanks!
just curious! thanks!
Check Out This Massive Send From Little Sahara Sand Dunes + Video
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Looking For A Wheel Bearing Greaser?
After much research, I’ve found this is probably the best one on the market.
Axle-in and multi-port for even distribution without having to spin the tool.
Thought I’d share my findings for those in need.
Havoc Indistries
https://www.havocind.com/parts
https://www.havocind.com/product-pag...s-greaser-tool
Attachment 107545
Axle-in and multi-port for even distribution without having to spin the tool.
Thought I’d share my findings for those in need.
Havoc Indistries
https://www.havocind.com/parts
https://www.havocind.com/product-pag...s-greaser-tool
Attachment 107545
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