ok so I put a new belt on my 2002 sportsman 500 and now when you start to give the bike gas it engages hard and makes a clunking sound so I took the cover back off and did it one more time with my hand touching the secondary clutch and it felt like it was coming from there. So I put the old belt back on and took it for a ride in the yard and it stopped doing it so I put back on the new belt and it started to do it. Is it possible or common for the secondary clutch to go bad or can it be the primary clutch?

 

Any chance you put the wrong belt on?? When you've got the cover off, it might not be a bad idea to dissasemble the clutches and check for worn buttons and loose parts.

 

yea check if it is the same belt same length. someone on hear said they put a belt on that was too long and it had similar problems.

 

I got the right belt. is it very hard to dissasemble the clutch?

 

i havn't doneit befoer but i reamember people saying it doens't take any special tools you need snap ring bliers to take that ring off he back but they said it was spring loaded and you have to whantch how you take it apart to put it back together right.