We received 3" of snow today so I thought I would do a couple of laps around the yard before our trip to the UP this weekend.... being that she's brand new I wanted to make sure that all is well. Here's what I found...

I noticed a slight clunk and can feel the sled lurch (during the clunk) at VERY slow speeds. I opened the hood and the frequency of the "clunk" does not relate to jackshaft rotation or secondary clutch rotation. It also does not relate to track rotation.... meaning the "clunk" is faster than one complete rotation of the track. It almost seems like it's related to one revolation of the chain. Not had much experience with this type of problem so any insite is appreciated.

Keep in mind this sled has 1.4 miles. I'll call the dealer tomorrow and see what they have to say... I just don't want to hear "bring it in and we'll have a look". That would screw up the weekend. Oh well... we will have to see. Thanks!!

*** ADDED NOTE ***

The TEAM secondary has a VERY SMALL amount of play both when I rotate it by hand (CW & CCW) and when I pull and push on it. Is this normal???

*** ANOTHER ADDED NOTE ***

A buddy just rode over from down the road... he has an 04 700 XC SP and his TEAM secondary feels EXCATLY the same as mine so that's not it.

huh....thats weird. but you are right about what the dealer will say......just bring it in. what you might want to do is elevate the back of the sled off the ground and either slowly rotate the track by hand and see if you can isolate the problem that way. or just start the sled and run it with the track elevated.
here is another dumb question. did you possibly run over a stick or branch in the yard? maybe something is just stuck between the track and suspension. just throwin' out ideas here.

the little side play with the team clutch should be fine.

It was the belt.... wierd.

was the belt to far down in your secondary..shifting to quick

Nope... the seconday was completely closed. The duration of the "thump and lurch" was about the speed of 1 chain/belt rotation. Checked chain tention and adjusted to 20 in. lbs. like the manual said and no help. Keep in mind I noticed this while traveling REALLY slow... like 1 or 2 MPH.

The only thing I did after inspecting all of my studs and chain was change the belt with another NEW one. During the process of changing the belt you have to insert a special tool to manually open the TEAM secondary. So either the origional belt had a bad spot OR there was something funny happening with the secondary which by manually opening and closing it, cured it.

Either way... all is well now.

On a side note, after I got the driveline in order I felt it was safe to crack open the throttle a few times last night and OH MY GOD!! Let's just say the headlights were pointing at the tree-tops a few times. This sled is a POWERHOUSE!! Track stands-R-us!! Plus this thing is running PIG RICH with the pre-mix gas the dealer filled er up with. One of my plugs fouled out after 10 minutes of operation and the smoke... WOW!! Can't wait for this tank to run through so I can see what she's really like!!

Glad to hear it was an easy fix. I can't wait to get to try mine out. :devil: Question for ya. While waiting for it to snow have you been starting it up in the garage and letting it idle then revving it a little just to hear the exhaust and smell the 2 stroke fumes? I have and I wonder if it has flat spotted the belt. And boy does mine smoke up the garage.

Not too much... but it's entirely possible that it has a flat spot. I guess it would be caused buy reving it up until just before the secondary moves. The primary would cause the flat spot, right? I would bet money that this is what happened... good call!!

I'm still going to the dealer today to see if they will replace it. Doesn't hurt to try. :p

the only way it could burn a flat spot is because your belt deflection is too tight. maybe your belt to sheave clearance is too tight and the belt was rubbing against the sheave at idle. the only other thing i can think of is maybe they put the wrong belt on the sled. that is a longshot though.

How did your ride go. Let me know. I put 90 miles on my xc800 this week. Definitely more power and alot smoother than my 02 800.

Zed

Update on the belt situation. Stopped by the dealer with the "defective" belt in hand and was taught a lesson. My last sled was a 440XCR and apparently with the higher displacement motors a person is MUCH more likely to burn a belt. They said that see it all the time... especially with first time owners of large displacement sleds. But apparently after they "school" the customer again on not "riding the clutch" or allowing it to "slip" (like pulling on to a trailer) they never return with a burned belt.

The thing is.... I know I did it, AND I know when I did it. Right after I studded my track I fired it up and with slight brake pressure applied (to not allow the track to spin fast while the a$$ end was jacked up) I gently gave it a little gas to assure there would be no interference issues with the new studs. At this point I hadn't ridden it yet... that had to be when it happened.

Summary of lesson learned.... don't pu$$y-foot around with the big displacement sleds. When you want to drive it up on a trailer or across a paved road... goose it a little, don't let belt stay stationary while the primary clutch is engaging on it. The weird thing is, I couldn’t really see a "burned" spot on the belt, and it looked fine to me. But once the dealer showed me where the spot it was obvious. I guess now I have another spare. :D

Funny that you say that. I've found that my 800 was really good a slow picking around and such and that it wouldn't be as hard on belts as my 600 was. BUT, when stuck in a little brook the other night I managed to smoke my belt good with one simple squeeze on the throttle. THat 's the kind of thing that drives me crazy! I belt and 2 plugs comes to $99 and change at the dealer here. THat's a significant chunk of change to be able to ruin with such an easy mistake to make.