Problem seen today with 2017 XCR 800 clutch alignment - HCS Snowmobile Forums

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Old 02-04-2017, 07:44 PM   #1 (permalink)
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Current Sled(s): 2015 AXYS Pr-S SB Ann 800, 2019 Indy 850.
Previous Sled(s): 2003 XCR 1100, 2000 XCR 800, 2005 Redline Revolt 800.
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Default Problem seen today with 2017 XCR 800 clutch alignment

A friend's new 2017 XCR with around 350 miles seemed to be wearing the new belt too quickly.

I used my Polaris AXYS alignment bar to check offset and a set of feeler gauges to check belt side clearance. Side clearance with his used belt was .050". A new Gates belt was .015".

This indicates that his old belt was worn around .015 because the Gates has always checked out about .020" wider than the original belt when comparing side clearances.

Then I checked offset. The tool wouldn't sit down into the primary as the secondary was too far outward on the jackshaft. There was only one .120" washer behind the secondary. I had to remove that one and install a .060" washer to get the proper alignment.

The problem is that the Factory Shop Manual states that you must always have at least one 16 gauge washer behind the secondary. In parentheses it says .150". According to my research, 16 ga is only .059". Thus, it appears that there is a misprint in the manual.

Or, the clutch has a deeper taper or the XCR engine is installed too far to the right in the chassis. My own AXYS had two .120" washers behind the secondary and I had to remove one to get proper offset.

Has anyone else used the factory tool to check their own alignment? How many washers of what thickness were behind the secondary?
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Old 02-04-2017, 07:54 PM   #2 (permalink)
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Quote:
Originally Posted by patrioticinnovations View Post
A friend's new 2017 XCR with around 350 miles seemed to be wearing the new belt too quickly.

I used my Polaris AXYS alignment bar to check offset and a set of feeler gauges to check belt side clearance. Side clearance with his used belt was .050". A new Gates belt was .015".

This indicates that his old belt was worn around .015 because the Gates has always checked out about .020" wider than the original belt when comparing side clearances.

Then I checked offset. The tool wouldn't sit down into the primary as the secondary was too far outward on the jackshaft. There was only one .120" washer behind the secondary. I had to remove that one and install a .060" washer to get the proper alignment.

The problem is that the Factory Shop Manual states that you must always have at least one 16 gauge washer behind the secondary. In parentheses it says .150". According to my research, 16 ga is only .059". Thus, it appears that there is a misprint in the manual.

Or, the clutch has a deeper taper or the XCR engine is installed too far to the right in the chassis. My own AXYS had two .120" washers behind the secondary and I had to remove one to get proper offset.

Has anyone else used the factory tool to check their own alignment? How many washers of what thickness were behind the secondary?
I need to order the alignment bar .....I only have one washer behind my secondary on my 16 pro-s though
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Old 02-04-2017, 07:58 PM   #3 (permalink)
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I had 2 behind my secondary and removed 1, as I like some free play behind as well.
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Old 02-04-2017, 09:22 PM   #4 (permalink)
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I had one .12 behind the secondary and the tool cleared. Has the drive clutch been off? Out of tolerance clutch taper and clutch sets inward?

Last edited by just-pinch-it; 02-04-2017 at 09:30 PM.
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Old 02-05-2017, 08:06 AM   #5 (permalink)
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Current Sled(s): 2015 AXYS Pr-S SB Ann 800, 2019 Indy 850.
Previous Sled(s): 2003 XCR 1100, 2000 XCR 800, 2005 Redline Revolt 800.
Location: SE Lower Michigan
Favorite Riding Area: Cadillac, Gaylord
19-20 Mileage:
18-19 Mileage: 849 so far
17-18 Mileage: 1280
16-17 Mileage: 1115
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I went back to my original records on 12-20-14 when I first aligned my secondary. I was mistaken about removing one .120" shim to get perfect alignment. I actually had to add one .060" plus the original two .120" shims to get proper 1:1 alignment. This indicates that there is a wide variance between sleds for the correct quantity and thickness of shims for good alignment. The reason has yet to be determined.

https://www.hardcoresledder.com/forum...es-oil-22.html
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Old 02-05-2017, 08:10 AM   #6 (permalink)
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Current Sled(s): 2015 AXYS Pr-S SB Ann 800, 2019 Indy 850.
Previous Sled(s): 2003 XCR 1100, 2000 XCR 800, 2005 Redline Revolt 800.
Location: SE Lower Michigan
Favorite Riding Area: Cadillac, Gaylord
19-20 Mileage:
18-19 Mileage: 849 so far
17-18 Mileage: 1280
16-17 Mileage: 1115
Riding Since: 1982
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Originally Posted by just-pinch-it View Post
I had one .12 behind the secondary and the tool cleared. Has the drive clutch been off? Out of tolerance clutch taper and clutch sets inward?
No. I also checked GSP Jake's 2016 Pro-S SB alignment last week. It checked out perfect. Didn't look to see how many washers were behind secondary, but soon will as he's supposed to bring it back for more changes soon.
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Old 02-05-2017, 08:53 AM   #7 (permalink)
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Current Sled(s): 2015 AXYS Pr-S SB Ann 800, 2019 Indy 850.
Previous Sled(s): 2003 XCR 1100, 2000 XCR 800, 2005 Redline Revolt 800.
Location: SE Lower Michigan
Favorite Riding Area: Cadillac, Gaylord
19-20 Mileage:
18-19 Mileage: 849 so far
17-18 Mileage: 1280
16-17 Mileage: 1115
Riding Since: 1982
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One more thing is we installed 10-68 weights and Gates belt. Tested at the lake Saturday. Stock gold primary spring. Was running at 8350 rpms with 10-66 weights and worn 1177 belt. Now at 8200 rpm.
Plan to go trail riding Monday. We'll compare performance again to mine at that time.
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Old 02-05-2017, 09:57 AM   #8 (permalink)
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Phil, Did you try rotating the primary and also the secondary several times and check alignment? Crank run out may slightly change measurements and also noticed some secondary clutches not running "true".
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Old 02-05-2017, 10:15 AM   #9 (permalink)
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Current Sled(s): 2015 AXYS Pr-S SB Ann 800, 2019 Indy 850.
Previous Sled(s): 2003 XCR 1100, 2000 XCR 800, 2005 Redline Revolt 800.
Location: SE Lower Michigan
Favorite Riding Area: Cadillac, Gaylord
19-20 Mileage:
18-19 Mileage: 849 so far
17-18 Mileage: 1280
16-17 Mileage: 1115
Riding Since: 1982
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Originally Posted by ninja_plumber View Post
Phil, Did you try rotating the primary and also the secondary several times and check alignment? Crank run out may slightly change measurements and also noticed some secondary clutches not running "true".
No NP. We did note what appeared to be some small amount of wobble when running. Might have been an optical illusion though. I'll certainly check both with a dial indicator though.
Thanks.
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Old 02-05-2017, 11:05 AM   #10 (permalink)
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It sure looked like my primary was wobbling yesterday when I was cleaning the clutch with it running. When you apply some throttle though it smooths right out.
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