Hi Guys, Just read the other post about secondary, and thought I would ask about primary. Have an 04 GSX and a 05 MXZ. Both 600sdi. The 04 seems to engage rather harsh...from a standing stop... When compared to the 05 when brand new...the 05 was smooth engagement, but now, after 350 km, the new 05 seems to be developing the same symptoms. It feels like the primary is reaching engagement speed, then quickly snaps or grabs the belt, causing a little clunk in the drive chain and away you go. It bothers me and I dont think it can be good for the drive chain??

Mine do the same thing but not everytime. I normally don't give er the juice until after it has engaged.

Are you sure your chain doesn't need adjusting? Mine loosened right up after a couple hundred miles when new and caused a clunk while taking up the slack upon engagement.

I haven't got one turn out of it yet. My old sled would slip at 70mph if it was loose. My current sleds engaged hard since day one. They are getting smoother but every once in a while it'll clunk.

I had a touring sled that would make that clunking noise sometimes too. Turns out it is the brake rotor shifting on the jack shaft. The dealer said that it's common and not to worry because, the've never seen one shear the keyway pin.

Originally posted by REVS UP@Jan 2 2005, 06:18 AM
Hi Guys,* Just read the other post about secondary, and thought I would ask about primary.* Have an 04 GSX and a 05 MXZ.* Both 600sdi.* The 04 seems to engage rather harsh...from a standing stop... When compared to the 05 when brand new...the 05 was smooth engagement, but now, after 350 km, the new 05 seems to be developing the same symptoms.* It feels like the primary is reaching engagement speed, then quickly snaps or grabs the belt, causing a little clunk in the drive chain and away you go.* It bothers me and I dont think it can be good for the drive chain??
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Like others have said - make sure your chain tension is tight. If it continues, take off the gearcase cover and check the torque of the bolt on the upper gear. It seems a lot of them are coming "finger" tight or even partially loose. They SHOULD be torqued to 30-55 lbf/ft and install new cotter key (that info is from the SHOP MANUAL).

Cheers,

G

Thanks for the posts guys, however, everything in the chaincase is fine...already did have it open, checked and adjusted tension. It is definitely drive belt or primary related.

Originally posted by REVS UP@Jan 2 2005, 06:42 PM
Thanks for the posts guys, however, everything in the chaincase is fine...already did have it open, checked and adjusted tension.* It is definitely drive belt or primary related.
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My 05 Rev does the same...it kinda sounds like a slap when it engages...I believe this is normal...on my last sled, my 02 MXZ, it did it all the time too and I never had a problem with 9000 k's on it
The dealer told me its just the way Bombi clutches are designed...
So just GIVE ER...and dont worry about it.... :hallo1:

Have you tried adjusting the belt?

This sounds like a belt deflection problem. If it has been engaging hard since new I would guess the deflection was never set correctly and all you have to do is adjust the deflection to bring the belt HIGHER in the secondary. If it has occurred over time I would guess the belt is worn and you just need a new belt. I had this hard engagement occur over the summer when testing a 600 rev on the grass using 419 ramps. They have engagement notch in the ramp and when the deflection was too loose(accidentally put on the wrong belt which was worn thinner than the correct belt and sat lower in the secondary), it engaged so hard it wanted to throw you off the back. This would not be as violent with stock ramps but I would guess it is the culprit to your problem. Good luck!

A worn belt was my thoughts. Please understand I am comparing an 04 and a brand new 05. The 05 was very very smooth engagement, and jumping back on the 04 I noticed the harsher engagement. After riding the 05 for 350 kilos, I am noticing it too is getting the harsher engagement. Both belts do not seem to be worn that much. Both sit up nice and high in the secondary....like new. I have not tried adjusting the belt. Other than the secondary clutch adjustment, I am not sure what other belt adjustment there is? Better go back and look at the crappy BRP manual... thanks guys

The RER helix has been known to clunk. The NON RER's are clunk-free!
Adjust belt deflection so belt is 1/16 over secondary, or so track creeps when on track stand. That'll allow you to get a lower starting gear ratio and also expand your clutches ability to shift through a broader gear ratio.

Thanks 440x and Deadman. I will give that a try. Wont be able to tell you how it works for a while, snow has melted away in our area. Damn

Originally posted by REVS UP@Jan 4 2005, 08:24 AM
Thanks 440x and Deadman.* I will give that a try.* Wont be able to tell you how it works for a while, snow has melted away in our area.* Damn
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I was told that the clunk is from the RER secoundary.They all do it.They do it worse when going from rev to forward.I have GSX,it does it.I had a Legend before this and it did it.Not pleasant but somthing to get used to.Before RER the clutch did not have double sided ramps because the clutch did not have to rotate backwards as with RER.