We have 2 ’05 Sportsman’s, one 500 & the other a 400, both with EBS and mileage of 3000 miles, give or take a few. The 500 clutch started making the occasional rattling noises on the last ATV trip to Wisconsin so I figured it was time to replace some parts. I tore into the 500 clutch and I was right. On the drive clutch there is a lot of loose parts, most of which can be easily replaced. Where I’m concerned is the rails where the buttons slide as the clutch shifts out are worn to the point where there is an indentation on those rails; to the point the weights were dragging on their side from about 3/4 to full shift-out. Plus for each set of button rails one side is a rough indentation and the other is a smooth indentation. The service manual indicates that the tolerance should be .000 - .001 and I don’t think I can get there with just new buttons. After looking at the 400 drive clutch the situation is exactly the same. I don’t have a spider removal tool yet to see exactly how bad the buttons are worn, but there is only about 1/8 inch of button left on all 6. Can the buttons deteriorate to the point they wear into the spider that much? Is this common? Would you guys I replace the buttons, weights, weight bolts, etc., etc, for about $100 per clutch or spend the $360 to buy a brand new clutch assembly? I’ve taken care of these machines over the years, but I guess I didn’t look close enough to these wear points when blowing out the clutches out every year. Plus I’m sure I’ll get the “you have an expensive hobby” comment again from my bride if I have to buy new clutches. Any comments would be helpful. Thanks for your help guys!!!!

 

If the slide towers are not grooved real bad rebuild.But the buttons wont last as long as the first ones did.
I would rebuild one and look on Ebay for a used clutch with good buttons and towers.
Then if the rebuilded one seems to do ok rebuild the other one and have a spare

 

I'm hoping I can just replace the worn parts and get-on-down the road without having to purchase new clutches. I've looked at EBay, but I'm not sure if the used clutches are any better. (That's where I have my spider removal tool coming from.) Has anyone else noticed these wear points on the towers and how did you manage the repair. Thanks again for your help!!

 

Once the wear grooves get too bad the clutch is junk.
When getting one from Ebay always ask about the towers and buttons

 

If you decide on new clutch get one for an 06 and up 800, better clutches, I,'m trying to find out if the xp clutch will work on the older machines, Dont know if EPI CHad has answered me yet I'll look.

 

I agree. The other thing to look at is how the grooves are. If they are worn really bad in one spot it will be harder to shim the buttons to fit good there and in the spots that arent worn as bad. One area will be tight or one area will be loose.