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Discussion Starter #1 (Edited)
Dalton kit for mav installed, works as advertised, then belt blew up UPDATED 1ST POST


8/19/13 update at bottom

Had World of Powersports in Decatur, IL do my recall stuff, clutch bolt/grab handle/starter and while they were in there I had them install the Dalton clutch kit with the supplied spring, purchased from hunterworks, and a brand new factory 212 belt.

I picked it up today, drove it 1/4 of a mile at their place, seemed fine, but smelled a bit of belt....

unloaded it and drove it nice and easy for a bit, varying the rpm as I was told to do, still smelled a bit of rubber, but again, didn't think anything of it

Finally unloaded on it, shot a video of the rpm so that everyone could see how great it was (see below), that all went fine, then putting back home 2 miles later the belt let go. I put it back in the trailer and am going to take it back to them Monday, but I assume it'll be a fight...I supplied the brand new factory belt (bought from a dealer online) and I supplied an aftermarket clutch kit, and now my belt let go. I can't see them fixing this, or even taking any responsibility at all.

What do you think happened, folks?

I was at the dealer when they opened this am and they immediately apologized and agreed to pull it apart while I waited. It took about 20 minutes and then we saw the damage, the secondary bolt backed out and let the secondary slide off, through the cover and tore up the belt, the helix and of course the cover. The big parts were intact though.

They said they'd unbox a new recall kit, use the secondary bolt from it, and go pull a brand new maverick out of the crate and pull the helix, cover and belt out of it for me. They proceeded to do this, but found out that the 14's have an updated clutch cover that has an additional vent on it, just in the middle of the secondary area. Interesting. They then uncrated a leftover 13, stole the parts, installed them and sent me on my way.

The only issue, and potentially a big one, is that they did not have the tool to lock the secondary to torque it correctly (15 ft/lbs + 180degrees), he could only get it 45 degrees and then stuck the impact on it had me watch to be sure it moved the appropriate amount. I DID NOT LIKE THIS, and told him that, but it was apparently as good as it was going to get, and it appeared to move the right amount, plus they used red Loctite as well. I made sure to mention this to the service manager and he wanted me to drive it as soon as I got home and let him know.

The problem is that I'm 1:45 each way from them, so it's $80 worth of fuel and a huge PITA to take it back...so I hope this does it. Pics below.

Thanks for all the help and advice, folks.

JC

 

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I wonder if everything was lined up properly because it was burning the belt from the beginning.
 

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Discussion Starter #3
This is what I was thinking. They said they "had some trouble getting the secondary back on because that spring was so stiff"... Which doesn't seem right
 

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Then that's it. Because the secondary has to fit into some slots so it will be in line with the primary. I bet if you look at it, you will notice it's not straight in line with each other.
 

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Discussion Starter #5
The whole point of having them do it was that I didn't want to take it apart lol.

I'm not sure what I want to do.... But if it is that, I sure would like a new belt out of the deal, at least. Not to mention fuel costs for the 3+ hrs Roundtrip....

I'm probably screwed. Lol
 

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Discussion Starter #7
Good point, I don't know, could be something else, but there wasn't any banging or crunching.... Just squeal and burning smell
 

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Discussion Starter #9
Notably no pop, definitely doesn't move on its own.... I assumed it didn't break, they seldom do, I figure it's strings all hairballed up in there
 

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Like mentioned above, I they didn't line the helix up properly then it would have destroyed your belt and could have trashed the secondary also. Sorry man but I wouldn't trust a dealership to do my clutch work!
 

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Discussion Starter #11
Yeah I've done lots of them, but I figured they had it apart already.... Poor choice clearly. Lol
 

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when u floored it your rpm only goes to 7300 7400 7500 , doesn't go to 8000 and stay there like the other guy mentioned , so I wonder if something is dragging ?
 

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Discussion Starter #13
Nah that was normal mode. In sport mode it did exactly what it was supposed to. It's the second run in the video.

Felt great, obviously peppier than before. Then, well, not lol
 

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Discussion Starter #14
Also, along that line you don't really want it to go straight to 8k...the power is below that just a bit... And to that end, this kit might be 100rpm high... But still great
 

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ya peak power is 7850 - I just thought the other guys vid went straight to 8k with Dalton so I figured that's whats they all did , but yes ,lil lower rpm then 8k is perfect
 

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Discussion Starter #16
I guess I've decided to take it apart myself, take pics of every step, and see what I find. If it isn't misaligned.... Then I dunno, but if I find it misaligned or just plain broken, I guess I'll be at their door at 9am when they open Monday. :/
 

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I guess I've decided to take it apart myself, take pics of every step, and see what I find. If it isn't misaligned.... Then I dunno, but if I find it misaligned or just plain broken, I guess I'll be at their door at 9am when they open Monday. :/
If you want any chance of them covering this, i would not crack it open and let the dealer…...
 

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I will say that the dealer did not install right or torque something incorrectly. The kit itself can't cause the problem

I would not let anyone touch my clutch besides me. The torqueing and cleaning of the primary taper mating points is crucial on this unit.

Todd
 

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I'm not having any problems since my dalton kit. No belt smell at all and mine goes to 7750 7800 7900 for a little bit then 8000 after the clutches have already done there thing. I would say mines working exactly how it should. I think ur dealer screwed something up!!
 

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Discussion Starter #20
The thing about letting them break it open is that it's unlikely they are just going to jump right on it, so it's not like I can watch them do it, which would allow for them to say it was anything.... Not sure they would, but not sure they wouldn't... First time doing business with them.
 
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