Hi, I am new to this forum. I have a 2000 Polaris Sportsman 500. The other day, I heard something rattling inside the belt cover case. I took the cover off, and I found several little pieces of plastic. I called the dealer and they are not sure what they might be. After looking at drawing of the clutch drive, I was told that it could be a limiting nut in reference to the EBS. The dealer said that the nut is plastic. The question I have is, can this plastic nut be seen without taking the clutch off or apart (not sure if its missing). Also, if this part is missing, is it needed and will I cause any damage by running the machine without it., Thanks

 

welcome to the forum. i think your refering to the jam nut just behind the outer sheeve of the clutch. i would think you should be able to look at the plastic pieces and see if it was once a nut like having threads on the inside or maybe square corners?either way you should be able to see the nut still installed if it was there. another thought is that either way if its not the nut and maybe clutch buttons that(small little pucks) slide up and done on the spider i would take the clutch off to check it all over and maybe have it rebuilt in need be.

 

Thank you, I will look today and see if that jam nut is there. Do they break? The pieces do look like they do have threads, but it does not look like a nut. The pieces are small. Question is, if the nut is missing, does it affect the performance in any way and should replace it? I took it for a ride without the belt cover on, and it seems fine. Thanks again

 

Yes the jam nut is plastic and will break. Most of the ones I've had trouble with just back off from the spider and limit clutch travel and speed,but I've found em broken also. Just remove the clutch cover(clutch doesn't have to be removed from engine) remove the 6 bolts from the clutch bearing cover,remove the spring, and install the new nut(put a few drops medium Loctite on nut).(You don't need the special socket on the nut,just have a dull punch after you tighten by hand to "stake" the nut snug against the spider with out breaking the new nut!. This will usually stop the breaking or backing off problem. Then just replace spring and push down on the cover(will be under pressure from the spring) tighten bolts little at a time around the cover until snug(Mark or remember to line the cover plate up as it came off from clutch body!!) Jam nuts are designed keep the spider from backing off even though its just plastic! OPT

 

Thank you!!!

 

yep, as opt mentioned it is the jam nut and yes it does need to be replaced. 1-5/8" center bolt. and 6- 7/16' cover bolts is all that needs to be removed. just make sure you know that the cover is on under spring tension and you should hold in on it to remove the last remaining bolts and hold it on to reassemble it. do not over tighten it as it's only alum your bolting in to on the 7/16" bolts.

 

Thanks

 

I got the piece today. Which way does it go on? Flat side out or the side with the four half circles out? Thanks

 

Slotted side facing out! Don't forget a couple drops of medium locktite and just lightly stake the nut with a dull punch! OPT

 

Thanks again!