I purchased a 99 Sportsman 335 several weeks ago. This is the second polaris i've own and I've never heard the clutch make so much racket. The bike runs great and has plenty of power but the primary clutch is make a lot of noise but only when it's idleing. I've removed the clutch cover and inspected the clutches and replaced the belt while I had it off but everything looked fine. The bike has 1600 miles on it and the clutch has never been touched. Do you think it needs to be rebuilt? If so, does polaris make a rebuild kit or do I need to get one from like EPI? Also what special tools would I need? I've had a couple of people ask me if the bike is a diesel.....

Graham

 

You don't need to rebuild the clutch, just replace the pegs around the carrier. After awhile the clutch vibration begins to wear the pegs down and you start to hear a knocking like your piston is slapping at idle. As soon as the rpms pick up and the clutch begins to engage the noise stops. I'm repairing the same thing on a 99 sportsman 500.

Solomon's

 

What solomanatv is talking about is the primary clutch buttons and it takes a speceil wrench and holder to get them aprat.Your best bet is to take it off yourself and take the clutch to a shop and have them put in.

 

how much would this peg thing cost if i took it off and brought it to a shop, i have the same problem i think on my scrambler

 

Should only be around an hor labor plus parts not sure how much the buttons right off my head but if I remember right they are in the $2 range and the is 6 of them. Dont hold me to this cause its been a while since I did it.

 

Also, check inside the clutch cover to make sure it isn't rubbing, that can cause alot of racket at idle. To be sure, you can paint the inside of the cover a light color and go for a ride and take off the cover, if paint is missing, the cover is rubbing and needs to be replaced. It is common for the cover to heat up and over time to shrink.

 

Thanks for all the input! You described it exactly. It sounds like the piston knocking but as soon as the RPM's go up it's gone. EPI offers a cluth rebuild kit for $120 then I would need all those special tools to service it. I'm not sure if I want to do that or not but the Polaris shops around here are pretty lame. They would want me to bring in my whole bike as opposed to the clutch. The epi kit comes with more than just buttons. Do I need all that other stuff? Also I am thinking about upgrading to 25" tires. Currently I have 24" on the rear and 23" on the front. I may go ahead and change the springs in the clutch when I rebuild it. What is a good kit and will not affect my top speed too much? Thanks.