I had a belt start slapping the inside of the belt cover and after I took the only one off and was blowing everything out I noticed I had side to side movement on the one way clutch. It's a 2003 sportsman 700. Should the be any side to side play? The one way part still works like it's supposed to but I'm wondering if that might be what chewed up the outer edge of my belt.

 

One way fiber washer and brass washer probably need replacing. The brass washer inside the "cup" usually wears down to paper thin. Was told by engineer to use a .030 washer shim from inside of a rear non ebs clutch to use as a replacement for this brass washer. Washer size is 1.5 x 2.0 x .030 available at any hardware store.It will fit inside the cup,then the fiber washer and then the one way bearing. Should only have about .010-.015 side to side play measured between the fiber washer/one way bearing and inner sheath after installation. Plus on some you may have to add addition shims behind the rear clutch to align the clutches so the new belt will ride center of the one way.

 

As usual, Thanks OPT! I'll be sure to check that on the clutch I get to replace this one with. I went ahead and took it off to inspect it better and once I did I noticed several cracks from 1/4" to about 1/2" out from the center of the outer sheave. I've been looking on a few different sites and it seems that snowmobile clutches are EXTREMELY available. Are there any that would cross over and work on an atv? I'm finding several that look very similar but I don't know about their dimensions compared to the ones for atv's. And I've also heard that I think it's an 05 or 06+ 800 primary clutch would give me a little better bottom end?

 

I'm sure some other clutch parts would work and many be the same as a lot of snowmobile clutches,but Polaris doesn't have a crossover list.Where they differ is in the one way and washers/bushings on either side. Here's a list of models that do share your same clutch. Just keep an eye out on ebay.
Usage : 1321971

Year Product Model Assembly
2007 MIL SPORTSMAN 700 MV CLUTCH, DRIVE - A07MH68MA/ME
2005 ATV SPORTSMAN 600 DRIVE CLUTCH - A05MH59AK/AN
2005 ATV SPORTSMAN 700 EFI DRIVE CLUTCH - A05MH68AC/AS/AT/AU/AW
2005 ATV SPORTSMAN 700 DRIVE CLUTCH - A05MH68AK/AN/AD
2005 ATV SPORTSMAN MV7 DRIVE CLUTCH - A05MH68AP
2005 MIL SPORTSMAN MV 7 DRIVE CLUTCH - A05MH68MB
2004 ATV A04CH59AF SPORTSMAN 600 DRIVE CLUTCH - A04CH59AF/AH/AJ/AT/AV
2004 ATV A04CH59AK SPORTSMAN 600 DRIVE CLUTCH - A04CH59AK/AL/AN/AQ/AW
2004 ATV A04CH68AC SPORTSMAN 700 DRIVE CLUTCH - A04CH68AC/AF/AH/AJ/AT/AV
2004 ATV A04CH68AK SPORTSMAN 700 DRIVE CLUTCH - A04CH68AK/AL/AN/AO
2004 ATV A04CH68AU/CU SPORTSMAN 700 DRIVE CLUTCH - A04CH68AP/AQ/AU/CU
2004 MIL SPORTSMAN 700 MILITARY DRIVE CLUTCH - A04CH68MB
2003 ATV SPORTSMAN 600 DRIVE CLUTCH - A03CH59AA/AF/AG
2003 ATV SPORTSMAN 700 DRIVE CLUTCH - A03CH68AA/AC/AF/AH/AL
2002 ATV SPORTSMAN 700 DRIVE CLUTCH - A02CH68AA/AB/AC/CA/CB

 

Thanks OPT! I see comet makes a clutch setup for "All Polaris Models" which really makes me leery to start with but it doesn't have the EBS option. TEAM/EPI makes one but I don't know about it having EBS either. I need to call them on monday and find out. The big question is, how much difference would it make not having the EBS setup on the primary? I know it's a fairly heavy machine and I have taken a liking to not needing the brakes unless I need to stop completely/quickly. But better performance is... well... BETTER! I'd really like to keep the EBS characteristics of the stock clutch, but if it's going to cost me $100+ more then I may just have to keep an eye on my brake pads

 

When the Sportsman 500 first came out it had a non ebs clutch and most people didn't complain as four strokes normally have a natural braking effect once off throttle. Only a few complained and then on later models ebs clutches became an option or came stock on higher end models.Ones that screamed the most were the Sportsman 400 2 stroke riders. Descending hills took a hand full of brake along with a little throttle to "load" the clutches up so they could slow down. Giving throttle down an incline is against most people's thoughts and I even installed a couple ebs clutches on 2 strokes for people. After a few years all 4 strokes came with the ebs clutches,but some liked them and some didn't. I even installed non ebs clutches on some customers machines that didn't like the ebs system.. I've gone back and forth on clutches over the years..

 

I had to get used to blipping the throttle going downhill on my old 2 stroke trailblazer so I'm not against it by any means. But if the 4 strokes have a good bit of engine breaking naturally then I'm sure I can get used to it. Thanks for the input OPT!