sanding the inside of the sheaves would be bad if you don't do it right. Could take away from your top end a little bit by not letting the belt ride as high on the primary or as low on the secondary. On the secondary youw would have to do it right to get it so the belt sits nice and high when the clutch is disengaged and real low at top speed.
dependent upon how well you sand it. If you don't go to a real fine grit the sheaves will be rough adn wear the belt when it slides up and down. As for slip if you feel it they are pretty slick now so I can't say for sure. I can't say how to do it just can';t think of it. A lathe if you have access to one.
For running with out a belt, it depends on what clutch you have. A clutch like a polaris or comet 102c (or what ever it is) you can technicly do it, but I wouldn't go too nuts. But one like the Comet duster, has plastic "pucks" in it that will fly out when reved up. I've seen it happen
We have done the sand paper trick on some vintage stuff, but that is because they were steel and were rusted. They still never seemed to work properly though.
Don't sand it, just lightly scrub them. 50/50 mixture of water and rubbing alcohol, and use the rough side of a Scotch-brite sponge. It cleans the sheaves of light oil, bad films and especially the occasional belt residue that you'll see on the primary. I've done it on alot of older sleds and it works great! They have that shiny new look to them as well. I learned this trick at a machine shop.
Yeah, I would maybe leave it alone. It would suck to get some fingers or even your whole arm ripped off by it. Like Polaris-Man said, clutches are precision pieces of equipment. They don't take change easy.
The guys are right, I wouldn't play with this part of your clutches unless you really have some serious marks in your clutches. If you've got rubber deposits, or dirt on your clutches I would get a can of brake clean and spray the surfaces down. It really does an excellent job on them, and its not flamable.
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