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Discussion Starter · #1 ·
Last year I replaced all 4 bearings on both shafts
This year I took the primary clutch and secondary pulley off to get rebuilt.
When I put the secondary on, I noticed to much rotation of the jack shaft and thought the chain or tensioner was to blame.

I decided to take the chain case apart. here is what I found.
the lower sprocket with the three buttons engage into three holes of the opposing sprocket. This is where the slack is, but there is no evidence of wear.
is this normal?
It seems that the buttons do not have a tight fit in the holes.

P.S. the auto tensioner is doing its job.
 

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They will have a little bit of play so it is easyer for them to slip into the holes. shouldn't be a lot of play just a little bit.
 

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Discussion Starter · #3 ·
Jorgy84 said:
They will have a little bit of play so it is easyer for them to slip into the holes. shouldn't be a lot of play just a little bit.
There is enough play to cause about 5 degrees of free rotation in the secondary pulley. It translates into a clunk between accelerating and braking.

When I try to rotate my Polaris secondary, (granted it has engine reverse) it rotates about .25 degress.
 

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Discussion Starter · #4 ·
put a new chain on last night.
For anyone wondering, the thin washer goes on first, then the 2 reverse idlers, then the thick washer.

It did not get rid of all the slop, but it god rid of 30% or so.
 
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