Hi guys,
OK here's my issue, I have a 02 700 sportsman. When I take off fast it really lugs the engine, it used to spin the tires now it just dogs til I get up to speed. I put a new belt on because I thought that was the problem. It seems like it may be a clutch issue. Top end is the same as it always was. Just getting out of the hole is the problem. any thoughts would be appreciated.
Thanks

 

Sounds like the ramp and buttons in the secondary are worn and not letting it shift all the way back down. The ramp is aluminum and the buttons are plastic. Once they wear down it will not shift right. Buttons are about 3.00 each x3 and depending on where you get the shift drum could be about $50.

 

i second the motion of 2 manytoys. i think using high range in real hard areas take their toll on the ramps.

 

Thank You I will check into that. I have done a lot of pulling with this machine. Is this something I can do myself?

 

Yes you can do it yourself. Just pull the belt cover off, roll the belt off and take the center bolt out from the secondary (rear) clutch. Then you can pull the clutch off. On the side that is twards the tranny you will see a big circlip in the center. You need special pliers for this. Put the clutch on the ground and put both knees on top. Once you get the clip off the clutch will turn and spread open from the spring inside. Just be careful and hold on to both halves of the clutch as it opens. It is under pressure. Once the clutch is opened you will see the ramp inside one half and 3 buttons on the other half. The buttons will be worn and the ramp will have grooves/wear marks from where the buttons ride. If these are bad then this is your problem.

 

It has the polaris roller secondary on it not the buttons.

 

we stand corrected, thankyou. is the belt sitting up top of the driven clutch. maybe the spring let go or the rollers are sticking. take it off and apart and colean it at the least.

 

Yes, When I changed the belt I thought it was awful high on the clutch, It seems to be sitting almost to high. Now what do you think? The machine has 1000 miles on it if that helps.

 

personally i would still take the clutch off to clean and inspect them. the belt should be at least level if not a little above.

 

Could it be a carb problem?