My Sportsman 500 HO has just started sticking in gear when idling so it never comes to a complete stop it just keeps easing forward or backward depending. It has also become almost impossible to change gears while the engine is running at all. The belt looks fine(although I am not sure what fine is since that was my first look at that belt setup), and the fluids are good. Any help would be appreciated.


Bankwalker

 

It sounds to me that your idle might be to high. It tells you how to set it in your manual. I think if I remember correctly you have to take off your left access panel to see the idle screw.

 

I hate to say it ….but you get about 800 to 1000 miles out of the clutch in that year and the sheave plates wear out nothing you can do but replace the whole primary clutch.

I have tried shims and every trick in the book and the bottom line is save your money just go and buy a new primary and it will solve all your problems.

Trust me on this I went thru it all !!!!

I may be wrong but if you do a search on here you will see some posts I did before.

Good luck

 

I'm not sure if the 02's have the same shift linkage as the 03's but mine did the same thing years ago. If you know what I'm talking about give it a try. The rods and balljoints are what may need adjusting.

 

it should be idling around 900 to 1100 rpm. do you have enough belt deflection (thats pushing down of the top of the belt when its off and making sure you can push it in about inch or so. pull it off and look at the sheeves if there peeling metal off their junk. just a few things to check. also make sure the clutch is opening up all the way.

 

No belt deflection if it's a ebs

 

I would have to agree on the idle being set too high. There is an adjustment on the throttle cable on the handle bars. This should cure the problem, if not then it's time to check the clutch.