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Discussion Starter #1
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.:dunno:

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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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.:dunno:

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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Discussion Starter #5
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.

http://www.hardcoresledder.com/forums/929-rush-switchback-axys-platform/1237481-breaking-new-axys-800-ves-oil-22.html
 

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Discussion Starter #6
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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Discussion Starter #7
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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Discussion Starter #9
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.:thumbsup:
 

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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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Funny that you found this on an XCR 800 as we had the same exact issue on a brand new XCR 800 snowcheck. You can't run less than the minimum that Polaris states as the clutch will rub when it opens. We were not able to get good alignment, was out roughly .030" the only way we could get the alignment right is if we installed an ES primary as that requires the secondary to be shimmed out further. Contacted polaris and opened a case for this sled. We were told by the engineers that they in fact think this will gain performance and to run it as is.
 

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Discussion Starter #12
Funny that you found this on an XCR 800 as we had the same exact issue on a brand new XCR 800 snowcheck. You can't run less than the minimum that Polaris states as the clutch will rub when it opens. We were not able to get good alignment, was out roughly .030" the only way we could get the alignment right is if we installed an ES primary as that requires the secondary to be shimmed out further. Contacted polaris and opened a case for this sled. We were told by the engineers that they in fact think this will gain performance and to run it as is.
Interesting. The shop manual doesn't say anything about different alignment depending on whether it has electric start or not. Same tool is used for both. I guess it wouldn't change the required offset anyway, just the amount of shims behind the secondary. That would explain why the non-electric start seems to have less shims behind the secondary.

Anyway, we aligned the secondary with only one .060" washer behind it. Then rode Monday in Northern Lower MI. We also installed 10-68 weights and all stock springs and helix along with a .015" side gapped Gates Carbon Fiber drivebelt. We then raced the XCR against my BMP piped, 22/41 geared, BD tuned 2015 SB on a hardpacked road several times. This time we were much closer than when he was running the stock 10-66 weights and stock badly worn belt. This sled is now very fast for a stock pipe. He was about 2-3 sleds behind at 96 mph on the speedo. I was at 97 mph. He was pulling 8200 rpm versus 8350 before hand. I was at 8350. The sled owner is very happy. He still only averaged 15 mpg and I was 18 mpg.
 

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Ouch, tell the proud new owners of their XCR's they aren't real.:whistle:
In reality, they are a natural evolution of a great moniker.
Long live the legend, the XCR!
 

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Ouch, tell the proud new owners of their XCR's they aren't real.:whistle:
In reality, they are a natural evolution of a great moniker.
Long live the legend, the XCR!
I didn't intend to hurt anyone's pride. Bad choice of words I guess. Just curious is all.
 

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Discussion Starter #19
I can attest that the new AXYS 800 HO is faster 0-80 mph than all the triple 800 XCRs that I've raced. Especially when geared at 22/41 as mine is. Granted, the older XCR has more top end because of better chassis efficiency. Nevertheless, if the AXYS chassis is race prepped, it should still have great top end.

The folks who say otherwise haven't seen just how fast a well set up AXYS runs. Unfortunately, most AXYS sleds aren't properly clutched from the factory and have poor clutch alignment. They also don't have enough studs of the proper length to maximize the hp to weight advantage. My own AXYS has 240 1.45" Gold diggers as does the 2017 XCR. In addition, the numerous protections hidden in the ECU programming cause widely variable performance.

All those triple XCRs in the pics as well as my own 2000 are geared at 22/40 and are stock piped with 192-240 carbide trail studs and run 390-400 mains. They also run 10-64 weights at 81-8200 rpms. They also have torque arms installed and properly aligned clutches.

They routinely beat most big triple XCRs, Cats and Doos. But, unfortunately, "only" average 12-13 mpg at best.
 
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