Primary clutch sacked out... again

So in addition to needing a new motor at under 1000 miles, my primary had a bad roller about the same time. I brought the sled back right after the motor job and they told me it was the clutch and wanted ~$650 for the job. I just do not think that is right. I bought an expensive machine new from a dealer and paid extra for the promotional extended warranty. I did the work myself for the $250 worth of parts it looked like it needed. I thought I was very careful but just 200 miles later it is apparently in need of the same $650 rebuild, and that is the claimed reason the sled hasn't made over 7200 rpm since the new motor went in.


I took it back to them this time thinking I had the clutch fixed including a new spring and belt. The dealer told Polaris that I had worked on it so definitely no coverage. Again, what a crock. Because I don't feel like being raped by your dealer I do some work and now for sure it is my fault? I have been successfully wrenching on things with motors for decades. I think it should have been done the first time because it wore out prematurely. Are we now accepting 1000 mile motors and clutches that crap out as wear items? that is a pretty pathetic standard for a $13,000 machine with an extended warranty that Polaris can't even find? The dealer says they don't know who the warranty company is either? Well who paid for the motor job guys? Neither side knows?


It is just a freak show. I told them to button it up I would come and get it and make other arrangements. I go out of my way to spend money at this dealer. I recommended my buddy to them who bought a new sled from them. This is how they helped me out. I get it, by the book right, fair enough. Do not expect me back nor should you expect positive referrals.


So with a quick search I found a new primary for $483. All is should need is the spring and the weights fitted right?. I could get new weights if needed, and the spring only has 200 miles on it. Any tips or tricks to getting a new one set up and working?


I have ZERO faith that this will restore the sleds performance. Pretty sure it has several other issues yet unresolved. It needs done though, obviously. The dealer made no offer the go with the new one for less, probably couldn't get full mark up that way I guess.


Seems like the dealer and the manufacturer have both forgotten that the money only comes from the customer. Customers have lots of other choices in the market. Lose one or two and you will be fine. Make a habit if this like I think Polaris has and best of luck.


Anyway, end rant. Tips on fixing my clutch issue?

AdrenalineAddict said:

You have to be very careful when replacing primary rollers. New pins and rollers are the way to go and need to be installed without scuffing the contact surface of the inside of the roller. New thrust washers should also be installed, and again installed with care, do not pinch the thrust washer with the pin when you press it in. The spider buttons should be shimmed or shaved to have as little clearance as possible without binding. Torque spider to 200 ft/lbs. and lock nut to 230 ft/lbs with a little blue locktite on the lock nut. Every now and then when pressing out the original pins you will get a little metal transfer and the new pins won't have any interference fit, if this happens you may have to raise the contact surface on the spider in a few places with a nail set or some similar tool. Make sure you replace the bushings in your clutch weights also. If all is done properly your clutch should perform well for another 1,000 miles or so. At 2,000 miles you will want to give the moveable sheave bushing a good inspection and may also want to replace the cover bushing.

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I did ALL of what you listed. I even bought an extra set of roller washers because I pinched the first one. It all went back together pretty well otherwise.


Definitely looks like garbage again, rough rollers, weights off to one side starting to dig into the aluminum.


I still think that 1000 miles of service is pretty poor, and the dealer wanting $650 for it? I do not ever recall in 20 years of riding having to rebuild a clutch at 1000 miles.


Anyway, how about setting up the uncalibrated new unit? Simple as it seems?

I am well aware of the fact that there are other issues with the sled. When you take it in and there are clutch issues, that needs to be addressed before they can start looking for other issues or they will keep blaming it on the clutch. With a brand new clutch maybe I can convince someone to find the other problems. Maybe... because the clowns at Polaris can't figure out who the warranty company is.


This will be my last Poo for a while, just can't take the run around anymore on this poorly built machine. It was a great one year machine. I have hardly been able to ride it this season and it is far from sorted out.


I will be using a different dealer. This already was a new dealer after the last one took 12 visits for the TPS and never fixed it on my '14 Pro. This dealer isn't any better. Guess I have a 2hr drive to my next two choices...


It will get a new primary and weights along with the 2 week old spring. I will try to proceed from there.

AdrenalineAddict said:

I was doing some serious bitchin' myself a couple months ago but finally figured it out. If you want your Axys to run properly day after day you will need to rebuild your primary every 1,000 miles, new secondary spring every 1,000 miles, new motor mounts every 1,000 miles, fresh belt when worn to 1.410" (about 500 miles). I wish the dealer would have informed me of all the above, they just stole $200.00 said everything was fine and I had to figure out the issues myself. It sure is a fun sled when working right, I was doing some wicked steep chute climbing in the Ruby Mountains this morning and had a blast, climbing over the bars trying to keep the front end down, spinning 8,100 R's to 11,000'. My 2017 turned 1,800 miles this morning and still runs strong after all the above were addressed.

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I think we all have a right to be bitching about it. 1000 mile intervals are pretty sad for a $13k machine. The incredibly poor dealer support system and obtuse "customer service" Polaris trys to provide are pathetic excuses for what they should be.


I will order up the parts and fix the sled myself. Exactly what I was trying to avoid having to do by buying new sleds. I love the sled but man Polaris sucks at building and supporting this machine.

I hit ebay for parts. Found a new take off primary from M&M in Mn for 280 shipped and a full set of new take off motor mounts from somewhere in Wa fro $180 shipped. Still less than the worthless dealer wanted to rebuild my old primary. I still would have had issues because the mounts are worn out. I did rebuild the clutch and it did pick up rpm, just never over 7700.


So riding a borrowed, solid fast reliable heavy old Cat tomorrow... I should have the parts I need to get the Axys back on the snow for one last ride next weekend.

Murph said:

7700 rpm-- you need to do the E-VES push pull test of the cable. make sure you are between 16-18mm.

I wouldn't be surprised if your cable is broken-- 7700 rpm is about all they will pull with a broken cable, or a stretched cable.

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7700 was right after the new motor was installed. That is how the worthless dealer returned it to me. I assumed they would have noticed if the cable was broken. I brought it back to them with the low rpm issue and they blamed the clutch. Slightly better but not fixed.


I will check the cable while I have it apart for the mounts. BTW rpm was down to 7200 max the last time out.