I got an 04 Sportsman 400, back in May the buttons went out on it in the clutch, had them replaced..... it has been ridden probly 6 or 7 times since then and not hard, when it needed to be in Low it was... put really NO abuse on it since the new buttons. Go riding last weekend and half way through the day the buttons start acting up again and they are shot again. Is this right, I mean i know they are plastic, but should they really be shot after 6 months and 6 or 7 rides??? What can I do to fix this problem permantly or at least longer than 6 months, I mean is there a different type of buttons i should use or what?? I know it is the buttons for sure bc the same exact thing is happening when they went out before. Also do need the spring puller that is like $80 to pull the clutch apart?? Any help you guys can give me is greatly appreciated. Thanks.

 

Are you talking primary or secondary.If you are talking secondary,you dont need any kind of puller at all.Just remove the cover and then you will need a 1/2 socket to get the secondary off.Remove the snap ring (careful because it is spring loaded) Hold down the helix then gently let it up.Once this is done you can take the halves apart.You will see the buttons,you can either replace them with stock buttons or you can get the ss buttons from HPD (highly recommend).When you get ready to put it back together,let us know we can walk you thru it.

 

if you let the buttons get too far down last time it could have messed your helix up. Thats wat happened to me the screws had marked the helix up pretty bad and the sharp edges were wearing the secondary buttons down rather quickly. good luck.

 

conig, the last time when the buttons went out it was road back to the trail head and pretty much was undrivable by time we got back, it would not move. So if it did mess the helix up, how much does a new on cost and are they hard to put on?.... I am flying blind when it come to clutches and their assemblies

 

You might think about a used secondary off of ebay.They go rather cheap and for the most part are interchangable.

 

If you do not want to have to worry about htis ever happenig again you need to go to a team roller secondary clutch total assemble costs about 270-280.00 you wil just have to bolt it on we wil send it to you assembled anready to go. You can check thme out on our web site or give us a call 651-982-0600

 

I had to do my clutch buttons at about 60 hours/600 miles. When I pulled my secondary apart it did not appear to have the 1/3rd rotation pre-tension on the spring that it's supposed to have. When I replaced my clutch buttons I re-installed the clutch assembly putting the 1/3rd rotation pre-tension on the spring. I have a sneeky suspicion that this is why the buttons wore out quicker than should be the case......but it's just a guess on my part. I'm now at 100 hours/1000 miles and so time will tell. If they go again soon I'll get the good after market buttons and be done with it.

The stock buttons go for $3/each and there are three. I had to do my helix as well because by the time I figured out that the buttons were worn out......the helix had become slightly scored too. A new stock helix cost $43.

Note#1......I polished the bejesus out of the new helix ramp surfaces with a power drill, buffing wheel and buffing compound to smooth them out and make them less abrasive on the clutch buttons. I think this may help the buttons last longer.

Note#2......A >GOOD< set of snap ring pliers makes the job of diss-assembly and re-assembly of the secondary clutch MUCH easier. Get a set of the largest size that will fit the snap ring holes. Get ones with long handles for more leverage and the task will be much much much easier.

 

My girlfriends 2005 sportsman 400 did the exact same thing with 247 mile son it. The delaer replaced the entire clutch setup & the belt under warranty.

Sounds like the 400's are having troubles with these.

 

The dealer replaced the entire clutch set-up just because the clutch buttons were worn out!.........WOW.

 

thanks guys, I ordered stainless steel buttons yesterday and they were not cheap... but my cousin is going to look at it and tear into it. The helix is what i am not sure about bc the first time it happened we let it go until it would not move anymore, however the dealer did not say anything about the helix when they replaced them so i am hoping that it is not messed up, we will find out when it all comes apart, thanks for the tips and i will let you guys know what happens.