Hello. First time posting here. I have a 2000 Polaris Sportsman 500 that has been used hard. A few weeks ago while I was riding it, I came to a stop and the engine died. When I tried to start it back up, it lurched forward. We had to push start it going down a hill to get it going again and of course the next time I stopped moving it died again. I can put it in neutral and start it, however I am unable to put it into any gear. It grinds if I try and will not go.

I am guessing this is some sort of clutch or ABS problem, but could someone point me in the right direction for fixing this. Is this something that is easy to fix, or is it going to be pretty complicated. If you need further details, let me know and I can get them.

Thank you

 

sounds like the ebs primary clutch is the issue. take the clutch off and take a peak or maybe post a picture and get back to us. this is assuming you can shiftit fine w/ its off right?

 

Ok, I will open it up this weekend and see what I can find. Yes, I can put into any gear while it is off and even start it with a little push help. I just cannot shift while the engine is running.

Thanks

 

its got to be a clutch issue for sure by the sounds. also check to see if it has any broken engine mounts and if the clutches are lined up.

 

i had the same problem on mine!try this,acess the shift rods frm the bottom of the shifter to the tranny and loosen the adjustment nuts and try adjusting the rods abit.seemed to help me havent aproblem since.hope this will help

 

If it died when you stopped and you were able to push start it the primary clutch had problems, maybe the ebs washers, maybe alot more, you need a puller to remove it and special tools to take it apart.

 

Check your belt also. If it is shot that will happen too. Had that happen once on my 02 700 when I bought a "heavy duty" aftermarket belt that tanked after less than 100 miles. I highly recommend only buying the polaris belts. They are worth the extra $.

 

For the shifting, take both rods off tranny and see if you can shift it by hand or ply bar. If you can then the tranny is ok ,you just need to adjust you rods. It does not take much,mine had a grind to get in gear but one turn on the linkage adjuster made it shift butter smooth.

I did not know you can push start a belt drive ATV?

 

You shouldn't be able to push start a belt drive wheeler unless the clutch is keeping the pinch on the belt or the one way bearing is locked up.
You need to get the belt cover off and see what you can find.

 

I finally got around to opening it up last night. The belt was chewed up pretty good. It had chunks missing from it so that will be replaced. The clutch looks like it is pretty bad shape as well. There appears to be some sort of sleeve or bushing that came loose. It is about 4" in diameter and maybe an inch and a half wide and very thin and soft. It is offset to one side of the clutch and preventing the weights from moving freely. It looks like it may have broken loose and lodged in there somehow. When running, the clutch never fully engages so the driven pulley is always spinning, hence the reason I cannot shift into gear. I am pretty sure that is not correct, but since this is the first time I have ever laid eyes on one of these, I would like a second opinion. I will try to get a picture up later tonight.

I found a video online on how to remove the clutch. Is it as simple as this guy makes it look?
http://www.youtube.com/watch?v=8_HhKSY3Ro8

To clarify what I meant by push start.. I was pushing it down a hill while bumping the starter, then jumping on. I was about 5 miles from home and did not want to push it or tow it that far.

Thanks for all the reply's.