so my friends 2005 sportsman 500 wasnt catching gears properly. He took off the rear driven clutch and opened it to find that the ramp buttons were all broken. He noticed the bushings, ramp, and everything else were in good condition so he just replaced all 3 ramp buttons. He couldnt get the tension of the spring back on right so he took it to a dealer for them to put it together for him. He put the clutch back on and test drove it. The high gears werent catching right so he took the clutch off again and noticed cracks on the backside of the clutch, the aluminum is in tact but looks shatterd in most places.

anyone have any idea what would cause this?

let me note that when he revs the motor you could hear what sounds like metal contact somewhere...

 

excessive heat is what i can think of. that sis another reason the buttons break form riding hard in high range and causing extremly higher temps in the clutch housing. just an idear.