Primary clutch issues have you seen this?

[dezertBandito]

Hey Guys,
I was working in the garage last week trying to get ready for my first ever race in a UTV the upcoming race with AVE Racing. I put on the spare belt to get the break in period complete during our planned pre run. I happened to look down at the primary clutch bolt as I was changing out the belt and saw the primary clutch bolt literally hanging out. Wow I thought to my self how long was that like ! and what luck I found this sitting in my garage! Well I continued to finish my belt swap and got out the torque wrench to tighten it back up. As I went to thread the bolt back in it never got tight, so I pull out the bolt and find this!:

The bolt literally sheered off! I have no idea how long it was like that for and have never touched my primary. I took it to my local dealer who was able to get the clutch off even though the puller obviously wouldn't fit but they said their extractors aren't able to pull the bolt out!! I had high hopes untill i got that phone call i was still going to make the race! Now they are recommending replacing the crank!! That bolt is not held in with anything so I am surprised that its not coming out. Have any of you guys had this happen to you? did the warranty company cover the repair? I am nervous i may get stuck with this bill because its not a "lubricated part" but its total BS. I see in the parts manuals that the part number is superseded by a new bolt that is stronger so polaris clearly knows about this issue.

 

[///Airdam Clutches]

the bolts shear off when the primary is slipping on the crank. typically from a poor or improper installation.

they need to get the primary off, by using a short puller and teflon tape and water

once they get the primary off they need to center drill the bolt, with a real center drill not off center with a bendie'bit from home depot. after its been center drilled, an ease out will pull them out with relative ease. i have used a pick tool to remove one before, and left hand drill bits. there is no tension holding that piece in, it should come out with relative ease. if the bolt was loctite'd at some point, then you may need to heat the piece of bolt with a propane torch to help melt the loctite. then it should back out with an ease out.

no that likely wont be covered under a warranty, much like brake pads. the clutches and clutch assemblies are typically a non-warranty item much like everything else on the machine that begins with a "B" such as belts, ball joints, brakes, bearings ect ect. all considered wear items and wont get a good nod from warranty company

 

[dezertBandito]

no that likely wont be covered under a warranty, much like brake pads. the clutches and clutch assemblies are typically a non-warranty item much like everything else on the machine that begins with a "B" such as belts,

Man, thats a real kick in the nuts.. They said that the bolt would not back out, the service writer said that the tech drilled with a sleeve that centers the bolt but the broken end would not back out, the extractor was bending.. Maybe the threads are screwed?

 

[sand shark]

It might be a little work if moisture got in there and seized up the bolt. But as Adam stated you should be able to get it out with lots of patience.

 

[dezertBandito]

Yeah, well my guess is that the tech at my dealer ate up the diagnosis fee to extract the bolt so now they just want to replace the part. not sure how to combat that.

 

[dezertBandito]

the bolts shear off when the primary is slipping on the crank. typically from a poor or improper installation.
company

The rzr has about 2,000 miles on it and the clutch has never been touched, do you think it was slipping for another reason? unless it was slipping from the factory installation

 

[george.felix]

You need to make sure its tight periodically....I mean your bouncing it over the desert i assume and 2000 miles is a lot of offroad miles. Just hit it with an impact now and then if you don't have a torque wrench....Also change the bolt once in a while. If your just driving it till it breaks your gonna break. The suspension needs to be checked wheel lugs etc or your gonna lose something at the worst possible time. Are you servicing the axles or carry a spare? If you just drive it without maintaining it then never go alone and carry a tow strap.

 

[dezertBandito]

You need to make sure its tight periodically....I mean your bouncing it over the desert i assume and 2000 miles is a lot of offroad miles. Just hit it with an impact now and then if you don't have a torque wrench....Also change the bolt once in a while.

Yeah I have already added this to my inspection list as of now, I have not heard alot about this issue, (until I went searching for it).

 

[Erik@BRP]

There is also a correct sequence to torquing the primary clutch. Red lock tight on the bolt and torque to 96 ft lbs. Start the car and rev it close to the rev limiter a few times. Turn car off and torque again, will probably take a 1/4 turn to torque to 96 ft lbs. Repeat, usually have to do this 3 times minimum! Each time you rev the car up the primary is seating further on the tapered shaft. If you only torque it 1 time the bolt is usually loose after a short time driving the car.

 

[BiggJim]

It happens...They arent that hard to get out. Service tech now days are just that techs....if the book doesnt give them step by step they cant perform the task. You will have to take it to someone with a little bit of patience and some skill to drill and extract. Myself id probably try a left hand drill first. If that didnt draw it out then drill and use an extractor.

 

[dezertBandito]

It happens...They arent that hard to get out. Service tech now days are just that techs....if the book doesnt give them step by step they cant perform the task. You will have to take it to someone with a little bit of patience and some skill to drill and extract. Myself id probably try a left hand drill first. If that didnt draw it out then drill and use an extractor.

I wish I would have see this before I took it into the dealer, I called someone local to me that advertises being a broken bolt specialist, I got about half way through explaining to him what problem I had and he finished my sentence. I guess Burt's and Mountain Motorsports send him cars all the time. The downside is that he says once the techs try to get the bolt out they usually screw it up which aligns with what I posted earlier that they cannot get it to back out.

 

[BiggJim]

I wish I would have see this before I took it into the dealer, I called someone local to me that advertises being a broken bolt specialist, I got about half way through explaining to him what problem I had and he finished my sentence. I guess Burt's and Mountain Motorsports send him cars all the time. The downside is that he says once the techs try to get the bolt out they usually screw it up which aligns with what I posted earlier that they cannot get it to back out.

The only way you can really screw it up is to break an "easy out" or Drill bit off in it. Otherwise it should still be salvageable.

 

[dezertBandito]

The only way you can really screw it up is to break an "easy out" or Drill bit off in it. Otherwise it should still be salvageable.

Well as expected the warranty claim was denied, if the bolt pro cannot get the bolt out, I am stuck paying for a new crank to be installed...

 

[sand shark]

Well as expected the warranty claim was denied, if the bolt pro cannot get the bolt out, I am stuck paying for a new crank to be installed...

Not surprised warranty was denied. Probably said it was a wear item. Warranties seem to be useless unless you want to spend the time arguing the dealer and the warranty company. 5 weeks later you might have your car back.

The bolt pro person should be able to get it out.


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[Glamisfan]

Probably won’t work for you, but another trick to try is let it idle for an hour. The crank will heat up, and the vibration sometimes backs the bolt out.

There’s also the Rescue Bit. Drills though anything, even a broken extractor or drill bit.
Rescue Bit Broken Screw Extractor Removal Tool 3/16" https://www.amazon.com/dp/B00G2FBP9C/ref=cm_sw_r_cp_tai_i_OtbaBbYTQHB02

 

[dezertBandito]

The bolt extractor guy in santa ana was able to get it done, anyone in so cal that has this issue I would reccomend going to him before going to dealer with the issue..http://brokentap.com/

 

[george.felix]

For most work on a sxs I’d suggest finding someone who versed in all aspects of the car. Your going to be better off in the long run since most of these guys own and run cars. Taking to a dealer would be my last resort. I’d even trust google first......