I have a 2002 Sportsman 700 that has almost 800 miles and 204 hours on it. I bought it last year and so far it has been a great machine. This is my first Polaris mostly Kawasaki 650's prior. I went on a Trip to The Forks Maine for three days and my machine performed great. My buddies Sportsman 400 was a mess the whole three days, blew two belts and was making a horrible noise from the primary (like broken belt slapping). His machine has 1700 miles and 408 hours mostly heavy mud riding and little maintenance.

I want to make certain my Sportsman does not end up like his, what maintenance items do I need to perform on the clutches, (bushings, buttons, etc).

Does anyone have a good source for illistrated clutch break down and rebuilds?

Thanks for your help.

 

I have a 97 Sportsman 500 with 7500 miles, I just change the belt ever 2000 miles even if the belt looks good and clean the clutch suface with brake cleaner . Same with my 2001 500H.O with 3500 miles.

407hr at only 1700 miles ! that means he averages 4 mph. I have 3500 miles at 370 hr. What kind of riding do you guys do?

 

maybe blow out the belt dust and check the belt. use low range when going through hard stuff and really slow and you should be fine. imo

 

My buddy rides slow and hard, all mud and little maintenance, the whole machine is in rough shape from my perspective. Riding I like was in Maine, 30 mph average. I just want to make certain my clutches are working as they should. I have the 800 dual exhuast header and intake as well as K&N filter and jetted.

If there is some maintenance I need to doo at 800 miles I am looking for guidence.

 

If you can find them on e-bay get the newer 06 and up 800 primary and secondary roller clutch for it, much better clutches, if you have any doubt about your belt buy the 800 belt. more expenisve but alot tougher.

 

I found a new in the box 07 800 primary and secondary clutch set with the belt on Ebay. It was a big improvement over stock.

 

I thought the 07 clutches only work on 07s ? and do you have to change Primary and secondary so they match ?

 

Sammysdog64--I ahve an '03 600 twin and spend a lot of time at slow speeds and also have spent lots of time in the mud. I have almost 3,000 miles and have had my clutch cover off once. I had some other things being done at the dealer and had them inspect everything. They said the clutches and belt looked great and did not even recommend a new belt. My advise is to make sure to use low when you should otherwise don't mess with it.