I'm having the same problem with mine, I took it completely apart and found that the inside sheave on the primary clutch has too much play in it and is making metal to metal contact. A new sheave is $100 or more depending on where you look, but I haven't ordered one yet. I posted about it and someone did mention that it's common for the sheaves to get too much play in them.

 

Thanks for the reply,

I will try to pull it all back down in the next few days and report what i find. I also forgot to mention that i thought i saw oil on one of the rollers. I think i really need to pull that apart and clean them up much better.

Can you actually tell me what inside sheave your are talking about from this diagram?

http://www.bikebandit.com/oem-parts/2004-suzuki-vinson-auto-4wd-lt-a500f/o/m147648#sch504287

 

Alright, here is the verdict. Pulled it back apart last night. I ran it without the clutch cover on and the whining I heard was for sure metal to metal scrape. Also there were large chunks of belt still left behind the secondary clutch that I would have never seen if I hadnt taken both clutches off.

Look at my inside primary clutch plate. The fins started clipping the plate behind it. You can see where the fins are worn down. Now, I start comping this piece to others I see on ebay, all the others have splines in the middle! Where are my splines? I can almost not believe that they have been wore down so perfect that they are gone???

Also on this same piece you can see the groove around the center that has worn down and I think is the reason the fins started clipping. Its hard to see but right around the center hole there is a lip on the inside about 1mm tall.

Anyone know why my plate has no splines and every other one I see on ebay does? did they really wear all the way out!! the plate fits good on the shaft still it seems.

I started the atv after I pulled off both clutch plates just to make sure the metal sound was not further in the case. Big mistake, without the pressure from the clutch plate oil started leaking out of the wet clutch seal. I really hope I dont have to change that seal, looks pretty difficult.


Random pictures below. I have now started cleaning the housing, there was a LOT of belt debris in there.

 

Some additional pictures. I didn't have my clutch holder tool yet so I improvised with the crowbar underneath the machine and used a 3/4" drive impact to remove the primary clutch nut, which seems WAY over torqued...

 

Seriously call RVSPerformance, this guy is the best at clutching. Tell him what kind of riding you like to do, if you run larger tires, etc and he can set you up with the proper clutching setup. Trust me it makes a difference. I have attached a couple links to this post check them out....

Suzuki

http://www.shop.rvsperformance.com/Suzuki-Clutch-kits-CK-Suz-SPI.htm






.

 

Here is a video of a clutch kit install....

 

Cool thanks I will check into it.

 

That explains my problem. Mine has no splines left either, I didn't know it had splines. Thanks for keeping posted, let me know how it goes.

 

Any Luck?

 

I just ordered a new sheave from suzuki parts house for $120 with the shipping. Before shipping it was $97.20 but it should be here in about a week or so, we'll how it goes.

 

Yup, got my problem fixed. I bought a used set (both sheve sides and the rollers etc) off ebay for about 100 bucks that was in good shape. I put them in and everything works! I feel like my belt has a little "slap" noise every once in a while but it might just be breaking in? I put about 20 miles on it sunday and it had a lot more pep then when the belt was failing before.

Installing the belt was pretty tough. I had no way to press apart the rear sheeves, so I took a rubber mallet and beat the belt into the groove while it had it off the atv, I just kept beating it in around 1/2 the groove until it pressed apart the two sheeves enough that it gave me the slack I needed to get it on the front roller.

Hope this helps anyone else!

 

Thanks it helped me, now I'm confident that when I get my new sheave next week I can finally go riding!

 

Got mine together with the new sheave and she is perfect now! Thanks for help, its greatly appreciated