I have a 2003 rev 800, when it engages it makes a popping/cluking feeling, like some sleds with electric reverse when you use it then go to drive again, that feeling and sound except it happens every time i start from a dead stop. Anyone know about this?

It's the buttons in the secondary coming in contact with the ramps on the helix. The spring in the RER secondary does not apply any torsional force on the movable sheave to keep the buttons in contact with the helix. Do your best to 'ease' into the throttle just enough to let the buttons make contact. Then hammer it. It may be time already to take the clutch off and check the conditiojn of the buttons. If you let it go too long, you will ruin your helix and possibly the movable half of your secondary.

Keith

Welcome to the world of RER. They all do it. You get use to it. Enjoy!

Mine do it and I don't think I'll ever get used to it. I ease into the throttle until it engages and then I let it rip. It'll do it when you lock up the brakes and then hit the gas too. I don't let it happen very often but it does happen.

Agree, just make sure you check your chain tension as well.