Hey guys/gals, quick question.

I just bought a 02 700 Sportsman which has a aftermarket clutch kit. I am unsure which one is installed. Never having one on any of my atv's before, I don't know what to expect with it. I have to rev the bike up just a tad before it takes off (and does it lol). However it makes like a grab noise when it engages it. I hessitate to use the word "snap" but kinda sounds like it when it grabs. I know it's the clutch b/c I can do it on demand lol. Is this normal with aftermarket clutches? Just looking for some advise.....

Thanks.

 

most likely have a high engagement spring in it. you may want to insepct it to see if weights are not grooved or if everything is still good shape. imo

 

Ditto!

 

I checked the tranny fluid - ok

Rear differential fluid - was a thick gray almost with a grease consistency. Added some GL-5 80-90wt Gear Fluid as it was low.

Front differential fluid - ok

Greased all the zerks

Started up the machine while on the lift. Noticed that while in high gear and my 4x4 switch off, the front wheels spin. If I turn the switch on and then off again...they don't? Tried to mimic this in Low gear and it works normally. Anyone see this before? Also, the clunk I hear right after the clutch engages seems to be coming from the clutch. It's kinda hard to tell noise wise but if I put my had on the black cover on the right side opposite from the clutch side...I can kinda feel it through the cover. I still need to inspect the clutch but just assume its a result of the high rev spring in the clutch.

Also, while greasing the zerks in the back....I noticed only one side had a rotor and caliper. Is that normal? Sorry for all the input...just trying to get my head around this thing. I love the machone otherwise :-)

 

You say the rear fluid was thick and grey almost grease consistancy? I'd be changing that. Sounds like it's had some water in it at some point. Used gear oil should still be a dark oil color to black but not grey. And yes it's normal to only have one caliper in the rear. The rear wheels work together so one will do but the fronts work individually, thus a caliper for each wheel. IMO I'd like to see two on the rear but it is what it is. When it was up in the air in high range could you stop the front wheels by hand? My magnum will do the same thing in high range with the awd off. I think it's just the front axles spinning fast enough that it get the wheels rolling but I can stop the wheel by hand with no effort. At least in my case.

 

Yeah I filled the rear differential up and figured I'd run it for a little but to move some of that grease like fluid around and the new gear oil that I added would help do that. I plan to drain it after a short ride and refill. Just trying to move it around some in there.

I didn't try holding the front wheels...I'll have to give that a try, thanks for the tip!!

Back tot he clutch, I have all the stock stuff. I'm thinking about putting it all back in to see what happens with that clunk noise I hear when it engages. I can get past that noise if its a normal thing on these...but what concerns me is if it isn't normal lol.