I read a ton and have done a lot on my 4-wheeler using these forums as a guide. I will put a pic of snorkel too!

I have a polaris sportsman 500 HO - 2002. I was in the mud testing out my snorkel kit and got in either really deep stuff or tires got stuck on a downed tree i couldn't see. So I heard a pop and i finally (a month later) got a chance to open up the clutch area and this is what I found .... i can obviously replace the parts, but is what I can see all I will need to replace?

P.S. This is actually wife's computer and she isn't the happy camper =(















Thanks a ton!

 

I's say the front clutch(kinda obvious) ,clutch cover seal(check cover for splits also and backing plate for damage or warping), new belt and definitely tear into the rear clutch and check /replace any worn parts! Plus while you're at it check the front motor mount for separation. I only had a couple "exploded' clutches from our "mud doggers",BUT you did a BANG UP job!! Good nick name I gave these two guys were "Terminator 1 and Terminator 2! You qualify for Terminator 3!! Good luck OPT

 

If I buy a whole front clutch do I need any special tools to put it on? Obviously I did not remove it the old fashioned way

Are clutches OK to buy used? Anything to watch out for when buying one?

 

Along with checking what OPT said, If you're gonna buy used take a look at the second pic the peice on the far left, between the bolts there is a wear mark on the inside where the clutch buttons rub back on forth on there when the clutch engauges and disegauges make sure it's not worn too badly and the buttons have a flat profile. Also, look at where the belt rides on the sheves for wear marks or excesive wear or heat marks. Looks like you might want to check on a new belt too, it looks a little chewed up. You will also have to remove the rest of the primary clutch and the removal tool will be the easiest way to get it off. But to put another one on you'll just have to tourqe it properly and make sure everything is clean before reassembly.

 

looks like the cover saved you alot of pain when that came apart. i would buy a new primary if you can afford it as no worry about worn out parts. you will have to use your spring and weights. check the weights and bushings if you buy used to see if there worn out as well as the spider ramps/buttons to se as theres no damge or excessively worn.

 

if you buy a new clutch buiy a n 08 and up 800 clutch, better clutch especially if you get the roller secondary too

 

Holy crap!!!!

 

They are interchangable?


Yeah, that would have ripped my leg open, glad my son wasn't with me!

I just went by the swamp where this happened, it's been like a month and a half, it was all underwater before, and I can still see the tracks where i was stuck. Sticky stuff!

 

I'm surprised it didn't do more damage to the cover. Not necessarily breaking it open, but I'd have thought the plastic would have had some deep scars in it.

Congratulations on not doing a half-assed job on it.

 

I was 100% sure I had just broken a belt, I kept putting it off tearing into it, I have been putting all my time and money into boat. So I was extremely disappointed when I found out that it was not *just* the belt. Belt is scarred up, outer cover has some scars, but i think it's still safe and usable, rear cover has some broken tabs, so will need to replace it so clutch can seal again, and obviously the clutch is useless.

It was just a simple "pop" sound, man I was disappointed when I started pulling the cover and could hear metal clanking.