Went out last week, my Sportsman 500 left me stranded 4 miles in....
Come home tear it down, thinkning it was some sort of tranny issue, such as the silent chain or something, turns out, My secondary clutch came off. THe outside half split from the shaft, well came unthreaded! Now the threads are destroyed and the dealer wants 380 for a new assembly.....
I was thinking I would take it to the machine shop and get the threads fixed first. Then I would assume there is a specail clutch tool that keeps the two halves from spinning as I am threading it back on correct? Any input? ever heard of this before? Seems like a design flaw to me...
Just buy the new assembly? Clutch tool? Do I need to buy one or does anyone know the threads/bolt size?
Thanks guys

 

Are you talking about the splines on the clutch sheath stripped,Or the inside threads on the transmission shaft stripped that hold the driven clutch? What year model? Ebs or Non ebs clutch? OPT

 

need more info as opt said

 

the secondary clutch assembly. it is basically two "half moons." The outside one came spinning off. It came off the threaded 37.5mm bolt that comes off the other part of the "half moon." basically where the belt sits.... one 1/2 came off...it is held on by one bolt and a washer that hold the entire assembly on the shaft in the rear....So it is not the primary drive. the one in front. it is the rear drive that spins the wheels. I am sorry if I am not clear enough. I know it is kinda tricky to explain.
The secondary clutch is sold as one assembly. The outside half of that assembly came off......I dropped it off at the machine shop today to get the threads fixed and I am hoping that I can put it back on without trouble, however, I am thinking I will need a "cluth tool" to do this....

 

First thing that comes to my mind if the clutch separated is that the "retaining ring" or circlip at the rear of the clutch somehow popped off putting pressure on the clutch sheaths and eventually separating???
If this is what happened, then its a first one on me unless it had been worked on and the circlip either broke or wasn't seated properly! Whether an ebs or non ebs clutch,they both are held together by the circlip. Don't know if this is what happened,BUT is the circlip still in the groove,or did it come off?? OPT

 

I would have thought there would be some type of clip or washer or something to hold them together as well. There was nothing in there or missing as far as I could see. When I removed the plastic cover to the clutch, the only part that fell out was the half of the clutch. Now there is a washer and a bolt that screw into the inside of the shaft, and they were in place, which I thought was strange. In the schematics I didn't notice a surclip, but I will look again.
THanks for your input.

 

Never asked which year model as there are about three different rear clutches used depending on year and which version,this would really help!(my fault!) OPT

 

2008 sport5sman 500 HO with ebs

 

Your model has the cam plate on the rear and this is where its disassembled for repair if needed.These four (4) screws have locktite on from the factory and I always had to use a hand type impact to break these loose! Under the plate is a snap ring if you look close (item 12) that holds the clutch shaft at the back along with the rollers and spring. On the the front of the clutch assembly is another snap ring (item 6) which main purpose is to hold the clutch shaft to the front clutch sheath. Its possible the rear snap ring could have broken or the roller assembly become damaged and pulled out separating the two clutch sheaths? If the snap ring is still on the front of the clutch,this is the only thing I can think of?? Never had one come apart,but anythings possible! OPT.

 

THere are not any bolts holdin the unit together. Really strange. Just one bolt that holds the secondary clutch on the splines. A washer on the blot tha doesn't even exceed the outside circumference, which doesn't hold it in. Anyways, got the threads fixed, threw some locktite on the threads put it back together along with a new belt. Going thru some slower belt break in procedures and Hope it holds on......Just s strange design....
I would think at least they bolt that holds the clutch on would have a bigger washer to keep it in there or keep the "halves" together....