I am new to the forum and could use some help. Just picked up a 2005 polaris sportsman 800. it has been abused as far as maintenance goes. has been in the water and mud was in everything. Engine fires up and seems to run fine except that it seems a bit sluggish. it does not cut out, sputter, or smoke. I replaced all wheel bearings and both differential bearings and seals. It will not sit still at idle and when you give it a little gas it jerks to get going then runs fine just not very fast. I have ordered a new belt but have not changed out. The shifter works good with the engine off but once it is in gear with the engine running it is very hard to move. It also is in 4x4 all the time. I unplugged the wire going to the front differential and it is still in 4 x 4. Any suggestions?

 

Welcome to the forum first of all....You might wanna check the engine mounts....If you have a broken motor mount it could cause a clutch misalignment which will cause difficulty shifting and might wanna creep forward if your in gear even without giving it throttle...I'm sure you'll get more responses..

John

 

I will check the motor mounts today. My belt should be here today and I will try it out also.

 

Its probably the ebs washers in the primary clutch, you need special tools to get the clutch apart to change them, you need a clutch puller a holding fixture and a spider tool, cost about $150.00, I would'nt ride it much this way, hard on belts and tranny.

 

Looking at the exploded view of the drive clutch, which washers are the possible problem. I plan on lifting this thing up about 16 " so should I just get a new clutch kit and scrap the original?

 

if you think you have problems now w/ this, you wait until you lift that far lol. did you check the primary clutch when you had the cover off for worn parts? what did the belt look like when you had it off and where did it sit in the secondary? did you put the new belt back on so you could read the writting on it(they have to go on this way). if the bike wants to creep ahead when sitting there idling or does not like to shift good its more like he menetioned, either the one way ebs busing or fiber washers are gone. you can not replace these your self w/ out the specail clutch tools mentioned. imo.

 

I have not taken the old bely off yet. It is worn on the sides and does have some burned spots on it. It sits high in the secondary with about 1/4" of the top showing.