Has anyone seen a primary do this?? I cooked a belt getting her off the trailer last weekend. Really lost the high end, replaced the belt and this is what I found.... Anyone seen this before? Actually looks like the belt got so hot it started to melt the clutch.... Any idea cost and labor to repair/replace? :dazed:

Looks to me that is right where the belt should be at when you are topping out the primary. Are you feeling the worn down spot? i would think you would have to replae it if it is looking that bad. Maybe you can find a used one and replace just that side. I don't really know just throwing out suugestions.

That pic is too fuzzy to really see, but It looks fubared. I would buy a new sheave from a 440. It is lighter and will let the engine spin more freely.
Check out my posts in the clutching section on how to change the sheave.

00MachZ Looks like the surface has melted spots, hard to tell from the picture. Dino

Thanks Guys... I have never pulled a clutch before.... Are we talking a lot of work or is it a fairly simple job. :dazed: I am pretty mechanical just havent done a sled before. I think I will need a clutch puller tool...anything else?

That happened to my 97 mach 1.I ended up just buying a whole used clutch off a crashed up mach z because of the cost to replace each sheave.I got the clutch for 300.00 and the sheaves were about 250.00 if I remember right.

If you can wait for a good swapmeet. Clutch parts are a dime a dozen.
How did you burn it up that high getting it off the trailer?

What you did was burn the belt at one point and put the typical thin spot in it. you will feel this spot as a rythmic jerking in the drive train from zero to about 25 mph. On the higher HP ski-doo's this thin spot will actually cause pittting in the sheave face (looks like a quarter size divit made by a sand blaster) further out in the sheave where the belt would run at higher R's and speed. The belt is trying to suck into this thin spot every time it comes around and it is "exploded" back apart when it hits the thicker far side of the burned spot. This action can be pretty violent when you're cranking 8000 rpm. The result is a dead clutch, DO NOT RUN IT ANYMORE OR IT COULD EXPLODE! I've seen it happen. You need to inspect both sheaves for any sign of abnormal wear and replace them if you find any, you cannot fix this damage. The moral of the story is if you have a high power sled and you smoke a belt throw the belt away. I have seen this happen on sleds as low as 500 fan twins. I don't know if this is a problem with polaris,cat,yamahahaha type clutches, I'm more familiar with ski-doo. This damage is not always the result when a burned belt is used, it is pretty rare, but is does happen and it is something to be warry of. Sorry, but you have a repair bill.

Removing a clutch is relatively easy...you need a clutch puller tool for that model and a clutch holding tool....you can get ski doo tools, or aftermarket ones from royal distributing or such a place....all you do is take the clutch bolt out, insert the puller (which is not a puller, just a boltish thing a bit longer than the clutch bolt) and crank it on until the clutch POPS off....all the while holding the clutch with the holding tool (a large hook)...

did it mess up both the inside and out side or just the out side half? if it's just the out side half it's about $170 us. for the part. when you put the clutch back together use blue lock tight on the inside part's and when you put the clutch back on tighten it to 75lbs.