I have a problem I really need help with. I bought a 1999 sportsman 500 that has been sitting for a good while. Got it running and noticed the belt was not disengaging. Cleaned all the primary and secondary clutch parts. The primary is fully disengaging, yet it still will squel and choke out if you stop. I replaced belt with belt p/n 3211077 hoping this may help and no help. Still only have about 3/4 of an inch belt deflection. From all I can tell the driven clutch is closing on the belt to tight. If I install the belt, the primary turns free, but when I crank it or when I manually turn the driven clutch it gets tight and will no longer turn free. I was just going to shim the drive clutch but it says the ebs belt deflection is non adjustable. I know the primary is not ebs, but the book says the driven it a compound ebs. What does this mean. The side of the ATV says EBS. Just need to know if I can add shims and if so what is the normal thickness to add. It currently has none in it. Please let me know. The alignment looks good by the way. Whenever it starts getting tight the belt is still in the center of the fwd pulley from what I can tell. Sorry for the long post and thanks for any advice.

 

3211077 is for a non ebs clutch. 3211069 is the one called for on the 99 ebs model. May or may not make a difference if you have a non ebs clutch on the front and an ebs clutch on the rear. Sounds like PO did some swapping out of clutches if he had problems. Normally on ebs clutches just shimming out behind the rear clutch solved a lot of problems if the clutches checked out okay.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse http://www.cyclepartswarehouse.com/f...1999&fveh=5486 I've had guys try this before and had problems.

 

Thanks for the response. I did some more looking and the rear is ebs not the front though. When you say shim behind the rear you are meaning in between the moveable a non moveable sheaves of the driven clutch correct? This would open the clutches to increase belt deflection. Also, in the manual it says their must be one spacer at least. None were on this one.

 

Never had to shim clutches internally,just added shims behind the rear clutch to align the front clutch with the rear clutch.This was on complete ebs systems. But with your mixed system of clutches and belt,the rear clutch should not be turning if it had the ebs front clutch with the one way bearing. Best thing I can say is to either find a non ebs clutch for the rear or change back to an ebs clutch for the front so you'd have a matched set of clutches again.

 

Well after researching more I found out I have an ebs front clutch. Once I figured that out I realized the one way bearing was froze. Dissasembeled the clutch and found the bearing destroyed. Going to look at the dealer for one tommorow so I can get it going.

 

Not your year model,but the specifics are close on maintenance and repair. If you don't have a manual this pdf will help.Index of /ORV Manuals/Polaris/1996-1998 - All Models