Well, after a long ride this weekend, I have managed to break a couple of things on my 99 Magnum 500. Fist, my belt and clutch cover is rubbing my primary clutch, and I can't seem to find anything wrong with it. It does feel a little loose, but nothing is broken. Also, my speedometer quit to. Any ideas for either problem? Thanks in advance....

 

well i have a 01 magnum 500 and it use to rub on the cluch cover but it went away after the gas stoped leaking on the clutch cover seal. and mine seems loose too but nothing is broke or anything. have you steped on the cover? dont do that! for the speedo the most you can do is look for a disconnected wire ( look in the head light pod) you might have to buy a new one. well this might help you.

 

i heard that polaris has had some problems with the speedo on the magnum's but i think that was the 2000 models..not 4 sure..does your 4 wheel drive still work? cuz if your speedo quit your 4x4 might have also? let me know

 

Four Wheel drive still works. THe speedo quit after I got stuck in a really deep mnud hole. Had to be pulled out by a Prarie 650, then I pulled him out of the same hole!

 

The clutch cover usually rubs the primary clutch when it has got hot and kind of shrunk up somewhere. These get kind of melted out of shape from overheating the primary clutch. (have replaced alot of them) this is caused by ether riding very slowly in high range, causing the belt to slip a little. and from overworking it in the mud and pulling thing out of mud holes. ALWAYS USE LOW GEAR IN THE MUD AND WHEN MAKING A PULL. As for the speedo. Take the right front wheel of and check the speedo sensor behind the brake disk you may have bent it or pulled the wires out of it in the mud.. Hope this helps.....[img]i/expressions/face-icon-small-smile.gif[/img]

 

I have a 2000 xplor 400 4x4 that both things happened to. The speedo still lights up but the needle moves all over the place forward and backwards the odometer I cant tell if its working the digital numbers are all scrambled like a digital watch that the batteries are going dead.4x4 still works. The clutch cover makes a slapping sound do to the fact that it was stepped on, it wore a groove in the inside of the cover and the sound went away. By the way, the speedo goes for $178.00 from polaris, alot of money for such a piece of *hit. Let me know what the problem ends up being.

 

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Hello,
1st time posting at ATV Connection, after lurking for sometime.
The clutch cover on my Magnum 500 is also somewhat loose. In the last few weeks, there is substantial noise from the clutch and or belt rubbing on the inside of the cover when the machine is first started. Once the engine is warmed up, the cover seems to "relax" and the noise stops. If I physically move the cover with my hand I can stop the noise also. I have noticed that the Sportsman 500 has a small metal bracket that helps stabilize the cover, which the Magnum does not. I am thinking that I will try and design some type of metal braket to attach to the cover to the frame for extra stability. There is an open hole in the edge of the cover, as well as a hole in the frame just ahead of the cover. Does anyone see this idea causing problems?
Ray

 

I am thinking the same,, just have not had time to mess with it. I think that a small metal bracket would definatly help. Why did Polaris not do this in the first place??