Was wondering if anyone could tell me how easy it should be to rotate the track by hand.
Is this a good way to tell how much resistance is in the system?

I know it is hard to turn the track with the belt off. If you try to turn the secondary clutch, the track definitly has alot of resistance...thats were all our HP goes :(

hey,
With the rear of the sled in the air it should not be real hard to move the track if you are holding the track and spinning it. There should be some resistance, but it should be CONSTANT. If it seems to bind in one spot examine the track section that is at the drive sprockets. Mark it (grease pencil, marker) and rotate the track several times, is it still binding in the same spot on the track? If so examine the area a little closer for wear or srewed up clips. If the spot of resistance moves or seems to repeat, remove the belt and try again. If it runs freely then examine the belt. It may just be new and not broken in. If with the belt off it still repeats check your chaincase. Is the chain too tight? The Oil too Black? Did you just replace any thing in the chaincase? Check the chain and sprockets do they run true or parallel? If nothing is found here go to the bearings? When were they changed? Do you grease regularly? I would start with the clutch/jackshaft bearing. does it move smoothly? Then the drive track Bearing, Grease it GOOD.

This is probably more than you wanted, sorry.
Later
Don

the trackshould turn freely with the belt off............with using just one hand to turn. With the belt on it will have to turn both the track and the belt and will a lot harder to turn.

I'd recommend getting a track tension gauge P/N 529021500 or use a good quality fish scale and a buddy with good ruler. Measure mid point of track. Pull the track straight down hooking the scale on a track window using a force of 16lbs (7.3kg) you should see 1-25/32 - 1-31/32 in (45 - 50mm) deflection. This is performed on each side of the track between the slide (hyfax) and the area between the metal track cleats. Finish by aligning the track (track should ride centered in slides with rear raised and sled running slowly) also observe slapping (tightening and loosening) of track contact with hyfaxes as that is sometimes a sign of track reinforcement belt damage. If the machine was stored with the track on the ground, it will take a "set" and have some tight spots which will eventually smooth out.

Hey Don,
Thanks for the reply,
Just what I was looking for, a step by step method of elimination.
Great Job and no need to apologize. I can always use more info like that