Thanks for the replies guys. I pulled my drive belt tonight and took a peek at it. It was about to separate from a crack between two of the ribs, the tops of the ribs were burned as well as the sides. From what I read on the Gates snowmobile website it did (or was about to) fail from wear and old age.
I'm going to clean the pulley faces with some 600 grit sandpaper and clean them down with some brake cleaner to make sure they are clean and dry when I put the new belt on. I also am going to pull the air box and grease the jack shaft bearing and main shaft bearing, as well as hit every zerk i can find on it.
I was also taking off the remains of the worn out wear bars and discovered that the bottoms of the skis look like swiss cheese, and where they aren't holed are rusted and severely pitted. I ordered a set of kimpex plastic skis as there was obviously excessive friction preventing the machine from sliding freely.
Having read more about clutches and the cvt system, specifically the driven pulley and its "feedback" it is probably perfectly normal to be at 7000 rpm at 40 mph in foot deep powder because the machine is keeping its self "geared down" because of the load, it was just the burning worn out belt that was being a problem.
The track moves freely and will free spool at idle with the rear blocked, and with no load the pulleys will very quickly move through the speed range so everything is free. I have gotten the rpm's to drop on hard pack when I get on it, once the belt stopped slipping and hooked up
I'm going to be away for work for about a week so I'll have a project waiting when I get back, and I will update then, and try and get some pics with the low windshield that's coming with everything else:-)
Newbie: 1987 Polaris Indy 600, Bored to 720 with billet racing pistons and high rev clutch, Gates Xtreme, Kimpex Plastic Skis, ODI Downhill Grips, UNI Pod Filters
Last edited by Bored 720 Indy; 01-13-2009 at 11:52 PM.