Steering; Drive Belt Not Operating Smoothly In Primary Sheave; Glazed Drive Belt; Erratic Shifting - Polaris 1999 Sportsman 400 Service Manual

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T
R OU BLESHO OTll'iG
Drive
Belt
Not Operating
Smo ot hly in
Primal")'
Sheave
I.
The drive pulley face is
rough,
grooved,
pitted or
scored.
2.
The drive
belt
is
worn
and/or
defect
ive.
Drive
Bell
Edg e
C
ord Fa ilure
or
Uneven Drive Bell Wea
r
I.
The drive
and
driven
pulleys
arc
m
isa ligned.
2.
Th
e engine
mounts
are
loose.
Glazed Drive Bell
I.
Excess ive slippage
.
May be
caused
by
sticking
brakes.
2.
Engine
idle
speed
set too high
.
Dri
ve Belt
Too
T
ight
a
t Idl
e
I.
Eng ine
idle speed
se
t
too
high
.
2. Incorrect
distance
between
pulleys.
3.
Incorrect
drive be
lt
length.
Dr-ive
Bell
Turns Over
I.
Incorrect drive
belt,
2.
Incorrect
drive
belt
alignment,
3.
Enginemount
broken
or
loose.
Brake
Not Holding
Properly
I
.
Incorr ect brake
adjustment.
2.
Worn brake
pads.
3.
Worn
brake
disks.
49
4
.
Co
ntaminated
brake pads.
5.
Sheared
key
on bra
ke
disc.
6.
Air
in
brake lines
.
Leaking
Transm ission
I.
Loose
bolts.
2.
Damaged
gaske
t
seal.
3. Damaged
seals.
4, Cracked or
bro
ken cas
e and
/or
cover,
Drive
C
lutch
E
u ga~e
s
Before
Specified Engagemen t RPM
I
.
Worn spring.
2. Incorrect
width.
Dri ve
C
lutch Engages After
Specified Enga
gem
ent
RP
~I
I
.
Incorrect
spring.
2.
\Vorn
or
damaged
secondary sheave
buttons.
Errati c
S
hifti ug
I. Worn rollers and
bushings.
2. Sc
uffed or
damaged weig
hts.
3. Dirty
dri
ve
pu
lley asse
mbly.
4
.
Wom
or
dama ged driven
pulle
y
ramps.
Engine
Bogs Donn
During Engageme nt
I. Incorrect
driven
pulley
width
ad
justment.
2. Drive
belt worn
too
thin.
3.
Incorrect
distance
between
drive
and
driven pulleys.
Dri
ve
or
Driven Pulley
Stic ks
I. Damaged
pulley
assembly.
2.
Movable
pulley
dama
ged.
3.
Dirty
pulley
assembly.
ST EE R I:' I IG
Description
o
f
handling
problems arc
subjective.
but the
following
items will provide a
start ing
point
from
which
to
troubleshoot
handling and steering
problems. Some possib
le causes
for eac
h malfunc-
tion arc
listed
in a
logical
sequence.

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