I took my '96 sportman 500 to ride this weekend and during a long ride all of a sudden it doesn't have the forward push to go up hills (like the belt was worn). Then the belt started slapping a getting worse so I changed it on the trail (it was bad) with a good used belt. Same thing, no power on takeoffs or up hills but will be ok if I get momentum. I thought the used belt was streched so when we got back to camp we swapped it out again with a new belt. Same thing no power on takeoffs. We took the belt off and spun the trans pulley in neutral and it sounds like some metal pieces are tumbling around in there. Thats as far as I have taken it. Any one have any thoughts on what could be wrong. I just dumped $1500 in parts for new shocks, steering, wheel bearings, etc, a week ago. The machine has 6,200 miles on it. aaaggghhh

 

WHEN YOUR BELT FIRST WENT DID IT LEAVE PARTS IN THERE??IF YOUR SECONDARY CLUTCH IS RATTLEING TAKE IT OFF + SEE IF ITS THE RAMP BUTTONS.

 

I agree with Mechanike, I don't think that it could be the tranny. I just went through the same trouble but mine was the clutch. I don't have the so called buttons like you do but have read a many post on them and I would deffinatly take a look.

 

What are these "buttons" your talking about? pardon my lack on knowledge on this.

When I took the clutch cover off to change the belt the first time the belt was shredded (only rubber parts). When there is no belt on at all I can spin the trans pulley and hear metal stuff inside the trans. We also have another '96 sportsman just like it and when I spun the trans pulley on that one it was nice a quiet

 

If you take the secondary off you will see what we are talking about. Don't be scared to take it off. This is an easy job. I do know that you have to preload to put it back put this is easy too. Click into the search box and type in things like clutch buttons and how to change them and you will be able to read a bunch of answered questions.

 

ok guys, I've had time to look at it and found that whatever is making the noise is in the secondary clutch. I took that off and took the two pieces apart and found all the little torx head bolts are sheared off flush where they bolt in at. The only thing in there was the big spring, the metal 3 prong thing, and 3 sheared bolts. So my question is what am I dealing with here? Any help would be awsome!

Thanks (yet again),
Travis

 

Bump. The 3 prong thing (helix w/ ramps??) looks to have some damage to each of the 3 ends. If I wanted to replace the whole secondary clutch would I have to go with the same year model or can I get one with EBS or something?

Thanks,
Travis

 

come on guys......NO ONE knows if they will interchange???

 

Don't Quote me ...but I do belive that they are interchangable
Good Luck

 

If you want EBS you will have to get an EBS primary clutch also, then they take a different belt too.