I have 1996 polaris sportsman 500 i am having issues with it grabbing the belt at idle it wont let me shift unless i shut it off.. Now i have checked the idle it is good i have rwplaced springs in the primary clutch shimmed the inside of the secondary also the backside to align the belt properly it is a new belt from polaris and is the right part number the linkages are all good the motor mounts are all good i am at a lose i dont know what im missing this quad is like new it only has 900kms on it and i have gone through everything.. If anyome has an idea please shoot it my way.. also it does not have the one way bearing in it, it is the non ebs model

 

You already checked what I would have suggested but OPT should be here in the morning and can give you some insight.

 

Shouldn't have to add additional shims to the inside of the driven clutch,especially with it only having a little over 500 miles on it. Shims at the back to help align the clutches and belt,yes I've had to do that often. Measure center to center the distance of the drive clutch bolt and driven clutch bolt. Should be 10 inches.If that's correct,motor mounts ok as you mentioned,I'd go back through the driven clutch,remove additional internal shims and check the ramp buttons,helix and spring are still ok. 2-2 position on spring,helix prewound 1/3rd turn.

 

Thanks very much ill tear into it again this week and do as you mentioned and let you know what i find