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Hi, a buddy of mine has a 600 Indy XLT tripple from 94 that eats through belts after just a couple of miles. I looked at the primary clutch and noticed something sticking out down in the middle, it's a bit hard to explain but i'll attatch some pictures of the clutch and what is happening to the belt. Has anybody seen this before and how do I fix it?
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1995 Polaris XLT Touring
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I think I see something funny with that clutch. I think it's broken or damaged.
I agree, something looks off on that sheave down near the shaft.

Easiest fix, find a new clutch to replace it. It needs to be off a triple as the crank taper is different from twins. I learned this the hard way when I bought from someone who "knew what they were talking about". If the spring and weights are in good shape they could be switched into the new clutch if it has different ones in it that aren't correct for your machine. Beware on ebay since many sellers just put "fits 400, 440, 500, 600, XLT, XCR" lists everything without knowing. The difference isn't significant but since the twin taper diameter is slightly wider, trying to install a twin clutch on the triple crank will bind it on the crank seal and won't spin.

Or just go with a new powerbloc clutch.

You can always check the distance between clutches and the offset alignment. Center distance of the primary and secondary should be 12", the offset from the back of the secondary to the back of the primary should be 5/8" with no starter gear, 1"with electric starter ring. Take a straight edge at the back of the primary that reaches the secondary and measure the gap.

Check that the motor mounts are in good shape since if they're crooked or worn down the primary will be sagging lower or in the wrong place and may cause these types of issues.

But it really looks like there's something off with that sheave.
 

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Discussion Starter · #5 ·
I agree, something looks off on that sheave down near the shaft.

Easiest fix, find a new clutch off to replace it. It needs to be off a triple as the crank taper is different from twins. I learned this the hard way when I bought from someone who "knew what they were talking about". If the spring and weights are in good shape they could be switched into the new clutch if it has different ones in it that aren't correct for your machine. Beware on ebay since many sellers just put "fits 400, 440, 500, 600, XLT, XCR" lists everything without knowing. The difference isn't significant but since the twin taper diameter is slightly wider, trying to install a twin clutch on the triple crank will bind it on the crank seal and won't spin.

Or just go with a new powerbloc clutch.

You can always check the distance between clutches and the offset alignment. Center distance of the primary and secondary should be 12", the offset from the back of the secondary to the back of the primary should be 5/8" with no starter gear, 1"with electric starter ring. Take a straight edge at the back of the primary that reaches the secondary and measure the gap.

Check that the motor mounts are in good shape since if they're crooked or worn down the primary will be sagging lower or in the wrong place and may cause these types of issues.

But it really looks like there's something off with that sheave.
Thank you for the input, i'll check distance and alignment a bit later. Do you think the clutch is repairable or does it need to be replaced?
 

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1995 Polaris XLT Touring
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To me it looks like something may be worn out in the bushings on the moveable sheave (parts 17/18 below) or maybe the sheave itself.

To take the clutch apart you need specific tools to hold everything together as the jam nut is tightened to over 200 ftlbs.

That being said, anything can be repaired, but whether it's cheaper to just buy new/used, it depends on how the shops in your area are for skill and prices. I would probably try to find a good shape used clutch for a sled that old. That's what I did. Or if it's in really good shape and want it to be used for a long time still, maybe go with the new powerbloc.

White Font Line Parallel Diagram
 

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A shop near here will rebuild and balance the clutch for 300 bucks. They specialize in clutches and do a good job. Look around your area, you may find a similar place near you. Starting Line Products in Idaho or Indy Specialties can also take that on cheaper than buying a new one.
 

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Looks like the belt rested at the bottom rubbing against the sides a bit to much. It got really hot. Then the secondary is showing signed of the belt riding up on top, out of the groove.
 
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