The primary clutch doesn't appear to open all the way when stopped. Never had any issues until this spring after the first drive. It doesn't appear to be sticking, just looks like it is set that way. It doesn't come all the way out to the lip. Tough to shift now and moves at idle. Any ideas what might cause this?

 

If you have the ebs clutch(2001 had the ebs and non ebs models)Polaris ATV Parts 2001 A01CD32AA MAGNUM 325 4X4 DRIVE CLUTCH Diagram Then sounds like the clutches may be out of alignment,belt worn,one way washers worn,etc. You can try to lower the idle but if this doesn't help,the one way bearing washers may be worn allowing the belt to drift over and touch the inner clutch sheath.This puts constant pressure on the driven clutch and makes for hard shifting and creeping. If it shifts ok with the engine off,then sounds like that's the problem. Look over this post,shows what needs to be done.Plus if the rear clutch needs to be shimmed out,you can mach up a washer behind the driven clutch at any hardware store to have a couple on hand. https://atvconnection.com/forums/pol...-creeping.html

 

I don't think it is EBS. The cover is not marked EBS and the center shaft between sheaves is smooth. The center between sheaves doesnt turn either direction. The belt was fairly worn but not shredded. I do notice a touch of in out play in the secondary clutch. Any more ideas? It does shift fine when engine is off, the idle doesn't seem too fast either.

 

Unusual for non ebs clutches to creep unless the clutches are out of alignment or using the wrong belt. The #3211077 Polaris belt is the best one out there.Aftermarket belts are sometimes too tight and too wide. Blow out all the clutch dust in an open area,use some brake cleaner on hard deposits if you have to.Then with the belt off crank it up and throttle up and down to see if the clutch works ok. May be as simple as installing a new belt and then look at the alignment of the rear clutch to the front as it's idling in neutral.The belt should be riding in the center and not touching the inner sheath. You can shim out the rear clutch if it's not centered.These are simpler clutches than the ebs, but over time the 6 guide buttons and two bushings need to be replaced in the drive clutch and the three ramp buttons in the driven clutch.

 

Thanks OPT I will change the belt and clean things out. The only thing that seems off when I look at it is that the clutch doesn't open all the way to the bushing on the end of the shaft.

 

Many won't open all the way flush with the washer and bolt while running at an idle. If it's too far back though the main bushing may be worn and sticking on the clutch shaft a little.This is where the brake cleaner can help clean things up and also push the clutch in and out by hand several times and see if it helps.If the clutches haven't been looked at in almost 16 years,might be time to check them out if a new belt and possible shimming doesn't help on the creeping.