Bad Hesitation

This is a picture of when I theroughly cleaned and inspected both clutch in mid January. Nothing was worn out, but fresh bushings for next year are in the plans as this clutch has 12000km on it. After I added weights, it engaged at 4200 rpm and maxed out at 8500rpm. Seemed to work awsome, so I never bothered changing the springs. Mite change the next year too.
 

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Whenever I reassemble the the clutch weights an pins, I do this.
1. Warm the pivot pins and weights.
2. Apply a coat of this dry film lubricant to the weight holes and pins.
3. I do it to the rollers as well.
image.jpeg
 
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Good advice.

Just pulled out the primary. Took off the cover. Nothing seems wrong anywhere. Everything moves smoothly. Definitely use some freshen up for next year. Didn't pull of the secondary but it looks clean and functional. I was hoping to find the smoking gun.
 
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Just because nothing seems wrong doesn't mean nothing is wrong. Shortly after I got my first sled, a 96 vmax 600, I was driving it and all the sudden I thought I blew it up. Nope, engine was fine. Figured out it was the clutch. When I rebuilt the clutch you couldn't tell anything was wrong with it. But put it back on after the rebuild and it works perfect now. Had a similar, but not the same issue on my srx and it was the secondary. Have to remember when it is pushing on the belt it only has resistance on half of the clutch. The other half is trying to go in further still and can cause it to bind just enough. I also had a problem with my viper this year. When I would go full throttle it would bog and never recover unless I would let off. Yet sometimes it worked fine for a minute. All I had was a new secondary spring to try. Put it in and it was good as new. Couldn't believe just the spring change did it. Hope this helps.
 
drew24 said:
Just because nothing seems wrong doesn't mean nothing is wrong. Shortly after I got my first sled, a 96 vmax 600, I was driving it and all the sudden I thought I blew it up. Nope, engine was fine. Figured out it was the clutch. When I rebuilt the clutch you couldn't tell anything was wrong with it. But put it back on after the rebuild and it works perfect now. Had a similar, but not the same issue on my srx and it was the secondary. Have to remember when it is pushing on the belt it only has resistance on half of the clutch. The other half is trying to go in further still and can cause it to bind just enough. I also had a problem with my viper this year. When I would go full throttle it would bog and never recover unless I would let off. Yet sometimes it worked fine for a minute. All I had was a new secondary spring to try. Put it in and it was good as new. Couldn't believe just the spring change did it. Hope this helps.
Click to expand...

Very interesting. Does it always feel like a bog? Like your stuck in high gear? Did your plugs ever show any changes when the clutch problems occurred?
Mine feels like all three cylinders are firing every second or third rotation.

Oh! That reminds me. Before my terrible ordeal with getting stuck, burning belts, braking off my steering, and being stranded..........

I did a test that mite give me a clue. I ran the sled for many kms in its happy zone of 5500rpms then checked the plugs, (See pic #1). Then I ran the sled and maintained 6500rpm right in the middle of the hesitation range for many kms. Fare longer then I ever dared before. This time the plugs looked damp. (See pic #2)

I know this thread has grown long and tiresome but I thank and appreciate everyone's participation with it. I may have to accept that I won't solve the mystery till next season ( this is going to bug me all summer) but it wasn't for lack of trying. Again thanks
 

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Try a different stator and magneto. It may only produce the issue at rpms. Both of these can mask issues very easily that check out fine visually and with a meter.

A long-shot is the starter circuits letting fuel by when the vacuum gets high enough. Check the plungers to make sure they slide easily, the rubber seals to make sure they are sealing and the seats to make sure they are clean. Might be covered in the write-ups on the Tech Pages.

Anyway, those black plugs look like too much fuel.

Don't forget the oil pump adjustment too.
 
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I know what you mean about driving you nuts all summer. Been there and it sucks. lol Keep checking things and you will get it. There are only so many possibilities it can be.
 
Just to give everyone an update. I ve gone for three rides in the last week. First was a short 4km, the second 12km, and two days ago I racked up another 40km.

What really surprised me is the mysterious hesitation is for now gone. Ever since I repaired my broken steering it's been running fantastic. WTF!!!!????? I'm happy I got to enjoy my sled for these last few rides without that problem , but I still don't have any sense of closure, nor do I feel the issue is gone forever. All I can do is enjoy the positives as they happen. I mite get one last ride before I store it for the season. The snow conditions have been detiriating fast. I still think it's one electrical wire somewhere. Who knows. Time will tell. For now all I'll say is how much I love my sled and appreciative of the nearly 2000kms of joy it has provided me this season. Bye for now.
 

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You likely have some wire chaffing around your steering gate and post. There are a lot wires going through that part of the harness.
 
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