My 2004 sportsman 400 is not operating normally in high-gear. It's very sluggish and a loud "ripping or screaching sound" can be heard from the primary. It looks like the clutch is not grabbing the belt, but I can not tell if it is the front or rear sheaves. The belt is new and in great condition. In low gear, it is grabbing better but not as efficiently as it was before.

A local ATV repair guy said that my sheaves needed replaced for about $800.00. I did find a brand new clutch for half and already had the bushings replaced. He said there were "teeth" that also needed replaced.

Does this sound like I need a new clutch? And if so, will a new clutch include sheaves, "teeth", and so forth.

Thanks for any advice you can give me.

 

the only way the sheeves would be bad is if the crome plating is coming off and you see rough spots that would eat the belt or a major grooves in the sheeves. check the secondary clutch to see if the buttons are broke or worn out as its a common thing to happen. if your in mud or working the bike do you use low range? this is hard on the clutches if you dont use it. just my .02

 

"Buttons"? Are these the "teeth" the mechanic referred to? I do not know much about these machines. Thanks.

 

How would I go about checking the secondary? What would I need to look for?

 

i have replaced the secondary buttons several times on my 04 400, but i run larger tires and play in the swamps and hills alot..thats the first thing i check when not operating correctly and is usualy the problem at a cost of about$12.00.. make sure you wind(pre-load ) when putting it back together, that was my only problem the first time i made the repair...

 

Outstanding, Thanks for all the help!!!!

 

Also, is there a special tool needed to remove the secondary?

 

no special tool needed to take it off and only a pair of snap ring pliers to take it apart.

 

Thanks again. I'm just another "newby"!