Hey Guys! – I just replaced the EBS drive clutch on my 2005 Sportsman with a new 2008 Sportsman 800 EBS clutch. When I put it together with the new belt I used belt part number 3211095, which is the same belt part number for the 2005 SP500, and the belt isn’t very tight and I can spin the driven clutch and the belt slips on the one way EBS brake. The belt is riding correctly on the driven clutch according to my service manual. Is it possible I need a slightly shorter belt? If so does anyone know the part number? I also looked into the belt for a 2008 SP800 and it is part number 3211113 and I believe it is the same belt length so I don’t think that will help any. Anyone have any ideas???

 

The belt number 3211113 should be correct for the later models with EBS. Did you change out the secondary clutch as well? I'm not sure if it will make any difference but, The 07-09 EBS will be a roller style secondary clutch, not the conventional style your accustomed to seeing on the older machines.

 

I did not replace the secondary. It is the OEM secondary that came on the 2005 SP500 when I purchased it new. I'll look at purchasing the belt you suggested. Let me know if anyone else has any pointers. Thanks again!!

 

I believe you need to replace the secondary with an EBS unit, I think the sheaves are differant.

 

In 2005 the SP500 machine came standard with EBS. Therefore the OEM secondary is an EBS secondary. Hope you guys can help. Thanks again!!!

 

Even though your 05 has a secondary that is for EBS it may be different from an 08. There was some changes on later models with EBS. Yours should have buttons vs the later EBS models have a roller type set-up. As stated before, the sheaves might be different. I'm not 100% for sure. A slight difference in the pitch of the sheave can make a difference.

 

the primary clutches may have differnt diameters as well or at the least the center differnce measurement might be closer on the 800 vs the 500? just guessing though.

 

I did that on an 03-700 but I put the 800 roller secondary on too then used the800 belt

 

That Kind-a sucks! I was hoping I could use my 2005 SP500 EBS secondary. Now I need to tell my bride I'm spending more money on the ATV... Ouch! i looked on e-bay and there is one '08 SP800 secondary or $199 (buy it now), but I'm always afraid these used clutches will need to be rebuilt. Looks like a new 2008 SP800 secondary fully set up will run about $550. sheez!

 

800 eoller clutches last alot longer then the standard buttons clutch set up so unless it has a million miles it should be fine.