[drzcharlie]

This is my third post about what I perceive as a problem that I am not sure what to do about. My 17' Maverick Max 1000r DPS starts engaging the belt at 2450 RPMS and that seems high to me. Once it does engage the belt, it sounds like the rear diff is going to get torqued loose from the machine.

This isn't a muted clunk, this is a tooth rattling, feel in the seat of your pants, metallic chatter as the belt engages. I've been told just to go ride it. I find it somewhat unnerving to hear this thing engage. Hence my concerns.

I'm hoping for some substantial feedback on this. There has to be someone on this forum that can venture an educated guess as to what the actual the problem is. The bottom line is I don't want this machine to strand me somewhere.

What I have done to date:

1. Inspected belt, found it to be glazed
2. Cleaned the sheaves, checked the one way bearing and greased per the shop manual
3. Cleaned the sheaves again with brake cleaner and a green scrubbie
4. Replaced the belt with a new Hunterworks belt
4. Same problem
5. CV Axles were 3 years old, so decided to replace them (yes, they seated properly and yes they were OEM direct replacements)
6. Same Problem
7. Greased all U Joints (the front one under the engine was a bear to get to) they also feel tight when moving the drive shaft from side to side.
8. Same problem
9. Checked the rear diff for tightness, it was tight and torqued to spec.
10. The clutches appear to be original but I pulled them both.
I checked the rollers on the secondary (no flat spots) helix not worn, sheaves looked normal without damage.
The primary shows no wear on the cover plate bushing, Spider rollers were not worn but have some play side to side but very little. the bushings on the weights appear to ok as do the buttons.

What the heck else should I be looking at?

 

[2020RR]

Burn it down!!!

How does the shaft feel that the secondary mounts on (transmission input shaft)? any play?

 

[drzcharlie]

Burn it down!!!

How does the shaft feel that the secondary mounts on (transmission input shaft)? any play?

Di

Burn it down!!!

How does the shaft feel that the secondary mounts on (transmission input shaft)? any play?

Didn't think to check it. Thanks though, I will do that soon while it's torn down.

 

[drzcharlie]

That shaft has zero wobble in it.

 

[jimclemjr]

How many miles/hours and how high does belt ride in secondary sheave at idle? What characteristics does it have at shiftout and rpm at high speed. You say you cleaned primary, was there any evidence of grease on it?

 

[2020RR]

only other thing I can think of is maybe there is an alignment issue between the primary and secondary.. if the engagement is that high then i would think it would have to do with the primary.

Have you ran it with the cover off and WATCHED the clutches as it making the noise?

 

[Hollywood X3]

Does it have a tune? With some tunes, your clutch engagement rises. But 2450 does seem high.

 

[drzcharlie]

As far as I know it has not been tuned. The previous owner didn't mention it.
And, yes I've watched the belt engage with the cover off. I took some time watching the revs while doing so. That's when I became aware of the belt engaging at 2450 rpms. When the belt engages it jumps around a bit and sort of chatters in the sheaves instead of running smoothly. The rig has 72 hours on it and 4015 miles.

 

[Hollywood X3]

As far as I know it has not been tuned. And, yes I've watched the belt engage with the cover off. I took some time watching the revs while doing so. That's when I became aware of the belt engaging at 2450 rpms. When the belt engage it jumps around a bit and sort of chatters in the sheaves.

Clutch in alignment?

 

[jknapier]

A motor tune doesn't affect the engagement RPM, only a Clutch tune (stiffer primary spring, weight profile) does that. A binding, sticky primary will take more RPM to move.

 

[Hollywood X3]

A motor tune doesn't affect the engagement RPM, only a Clutch tune (stiffer primary spring, weight profile) does that. A binding, sticky primary will take more RPM to move.

Yes, that’s what I meant, should have said that, but I thought it was a given.

 

[drzcharlie]

I took my car out to a 4/5 rated trail last Sunday and was not kind to it, I really thrashed it.

The clutches held up admirably but the noises are worse now. Engaging from a stop to moving is much louder.

I've decided to take the rig to Dirt Doctors here in Tucson for clutch work and to set them up for 32" tires. At nearly 5200 miles it is likely that the clutches need replaced or rebuilt by somebody that knows what they are doing.

I will post up afterwards with the results of what they found and what they did.

 

[skidoochris]

for some like me 2500 is way too low

 

[Sublimeshooter]

The rig has 72 hours on it and 4015 miles.

Average of 55MPH!

 

[2020RR]

Average of 55MPH!

Lets GO!!!!!!!!!!!!!!!!!!

 

[drzcharlie]

Remember I bought it used. The other guy had the car off road very little. The trailing arms were proof of that no paint chipped. They are now chipped and the plastics have Arizona pin stripes.

 

[10mm_]

Our average is 10 lol