I have a 2005 Polaris Sportsman 500 and I rebuilt the entire primary clutch about 700 ago and it worked fine after that but now it started making a really loud clanking sound and i put new rollers in it thinking that might be the problem because one was starting to become a little flat but it still makes the sound. Somebody told me the buttons may need to be replaced. does anybody have any ideas? Heres a link to a video of the sound http://www.youtube.com/watch?v=sG4cxJLI_N0

 

If starting to sound like a diesel then possible guide area where the 6 buttons ride! Maybe just need buttons,BUT if you see deep grooves where buttons slide up and down,this could be source of noise and this part of clutch not sold separately. I've seen some really bad ones,but hopefully you can just replace the buttons. SEEMS like I always give the worst thing first,but guess its because I've seen some really abused machines! I'm not trying to be negative,BUT trying to show the good and the bad that can happen! Good luck OPT PS heard sound on video,DO you have any buttons left????

 

I was just riding it around normally a couple weeks ago and it just started that sound after going a couple miles and has been doing that since, but it sounded just like in the video right away.

 

Also when clutch was rebuilt only 500 miles ago everything that wears was replaced: rollers, buttons washers, weights, bearings, Everything, and now its making the same sound as it did before, but after it was fixed it worked like new until it suddenly starting making the sound like in the video and after only going home about 2 miles away. I have not driven it since and have replaced all the rollers because one of them was starting to get flat, but it still makes the sound. Any help would be greatly appreciated. http://www.youtube.com/watch?v=sG4cxJLI_N0