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Rev limiter at 45mph...not spider nut HELP

12K views 29 replies 5 participants last post by  rynomx785  
#1 ·
Having an issue I hope some of the experienced gurus can chime in on. Clutch feels like its shifting lower in the rpm band than It used and hit rev limiter at 45 mph consistently. Once, the primary stuck closed because a weight was jammed, it killed engine when I stopped. Free revving in neutral freed it up. 48hrs, 700 miles, almost all dunes. 2016 xp4 1000
Heres what I know
Spider nut appears tq'd all the way down.
Weights look severely galled
Weights move freely and bushings aren't worn(no lateral play)
Primary rollers show signs of surface galling but spin freely and have no flat spots
Never have failed a belt. Tried a new one here for troubleshooting and behavior didn't change
Spider slides show wear but worst is only about ..045-.060 deep.
Secondary looks great

What i'm srtuggling with is how bad the weights look and the rollers have no flats

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#5 ·
Dann are those weights munched!!
 
#6 ·
The only thing that makes sense is that the spider was backed off, despite what I originally thought and that allowed the weights to rub under the spider before the rollers. Explains the 45mph speed limit, how one weight got stuck and how chewed the weights are compared to pretty good looking rollers.

If I have to buy a whole new clutch, I may as well go STM? Not much more and rebuildable. 48 hrs, pretty poor showing for reliability imo.


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#7 ·
Don't buy Stm!! Buy a used clutch off eBay.
 
#9 ·
I have over 2000 miles on my stock clutch, but I do maint. On it, keep roller clean and blow everything out after every long weekend my friends has over 3000 miles on hs, we ride mostly desert environment with heavy dust, and down in Baja , ? If the loose spider is part of the trouble or?
 
#10 ·
I blow it out after every trip. Rollers spin freely. They squeak a little but seem ok. Pretty much run it flat out all the time in the dunes without paddles and jump a fair bit. Bet I could get away with repairing it. TQ spider and get the Dalton weights. Its Currently at the dealer for warranty evaluation.

Since it doesn't seem like normal wear, I expect they'll warranty it. Seems like they don't always do the right thing though... We'll wait and see


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#11 ·
Still in the shop awaiting Polaris response. Got to thinking about repair options since the basket looks pretty nice. I am thinking of using the SLP spider and getting a Dalton clutch kit.
This fixes bad rollers, bad weights and offers a performance increase. All for nearly same price as a new primary...and it's rebuildable. Even if I got a new primary, I feel like the spider would have to be removed TQ'd and loctited.

http://www.ebay.com/itm/262772831892?_trksid=p2055119.m1438.l2649&ssPageName=STRK:MEBIDX:IT


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#29 ·
http://www.startinglineproducts.com/catalog.cfm?pageID=detail&catalogID=1&catID=105&productID=3172

I called and told them what I have and where I ride, they said the 56 is what comes in the recommended kit for my inputs. I know it was a risk in not just getting the whole kit, but I don't mind trying stuff out and I'd like to understand better how the clutches work and at what point changes take effect (engineer).
I'm betting I'll still be calling Todd for a Dalton at some point.


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