Re: 500 Scrambler belt tension adjustment
I own a 02 Scrambler and Sportsman, belt tension is adjusted the same way for both as yours is. This is done by removing or adding shims in the secondary clutch. #1 remove belt #2 remove bolt holding the secondary clutch on, do not over tighten this bolt when installing. #3 remove the clutch and bench it. THE CLUTCH ASSEMBLY IS UNDER SPRING TENSION AND YOU SHOULD TAKE CAUTION. On the helex there is several holes make note which one has the colored spring in it. Next there will be a snap ring holding the helex on the shaft. You may want to get someone to help you remove the snap ring do to the tension on the clutch. You can do it by yourself but it is better if you have help. if you have a Visegrip "C" clamp hold the bottom sheeth and turn the top sheet counterclockwise just a little and using your "C" clamp, clamp both sheeths. Take a rubber mallot and tap the helex down to remove the snap ring. Remove the "C" clamp while having a firm grip on both sheeths. Once the tension has been relieved noting spring position in the helex and bottom position holes. (You will need to install the spring in the same holes when putting it back together) Remove the helex, spring and clutch sheeth. Around the shaft you will find several shims, to tighten the belt you remove a shim. Shims come in different thicknesses. Check how many shims is in there and remove one to start and reassemble sheeth. Install spring in the holes they came out of and then the helex. This is where it gets tricky. While holding the bottom and top sheeth turn the upper sheeth counterclockwise and the bottom clockwise 1/3rd turn and put your "C" clamp on. Push down the helex and install the snap ring. Remove "C" clamp and install the clutch on bike. Test for adjustment by putting into gear.
If the bike wants to roll in gear then you have removed to many shims.
It may take a couple times to get the right adjustment.
I hope this helps and be carefull!!!!