Sportsman Primary Clutch
 

Need a little help...please. I have a 04 Sportsman that the primary clutch sheaves are not close enough to put tension on the belt. The belt just hangs there. Once the RPM's get high enough the sheaves do come together, but at low RPM's the belt slips alot. Is there an adjustment to get the sheaves closer or do I need to rebuild the entire primary clutch? Clutch does not appear to be an any type of bind, it moves freely. The sheaves are just too far apart to grab the belt at low RPM's.

Thanks for the help!!


Mike

Sportsman Primary Clutch
 

Have you checked your belt to make sure its not past the wear limit? That will cause you to have to much clearence. You need to measure the distance between the belt and your sheave it should be around 20 thousands. To get the sheaves closer together you will need to take shims out from behind the spider and it takes a special tool to remove the spider.

Sportsman Primary Clutch
 

Another thing I forgot to mention. When I took the bolt off that holds the primary clutch on there looks to have been a threaded bushing that was broken. The bushing was on the bolt when I removed it. Half of the threads are broke off, looks like it threads into the clutch where the bolt goes through. Could this be the problem???

Sportsman Primary Clutch
 

Yeah the plastic bushing is supose to be on the bolt. The bushing should be roughly a 1" to 1 1/2" long.

Sportsman Primary Clutch
 

Does anybody know what the measurement between the two halves(sheaves) of the primary clutch are suppose to be? Is there a spec for that?

Sportsman Primary Clutch
 

On your SP ? is it a 500HO or a 400? How many miles on it? Have you slipped the belt before? Have you had it where water or mud has gotten into the clutch? It sounds like you should take both clutches off and check for inner bushing wear on both.For the primary,, brake the spider lose and see what you have behind there or at least find out what you have to work with for a bushing. If it's a 400 non ebs your bottons could be broken inside the secondary.Either way on all polaris ATV's both primary and secondary should be takn apart every 1000 miles to check bushing wear or any other worn parts.This is in the service shop manual. A good air hose blowing out of the clutch compartment helps to keep the belt dust at a low.Which can also hender clutch performance.