Hi, I have 2005 Sportsman 500 with a clutch problem. 1 week ago, the clutch suddenly started to slowly engage at idle, and stall the engine (while the ATV was stationary). I removed the PVT cover, and found 3 problems:
1.) Belt was worn and had 1 crack in it (not too bad, but its 7 or 8 years old, so I replaced it)
2.) Shift weights and pivot bolts/pins were worn in drive clutch. Weights were not too bad, but the pins were worn, and the holes in weights were worn and sloppy so I replaced all the weights and pivot bolts/pins.
3.) Outer sheave bushing on drive clutch was separated from the housing. The bushing didn't look too bad, but I replaced it and re-installed with the correct loctite 609.

I also took apart the driven clutch, but could not find anything wrong. So I cleaned it, and reinstalled.

After all that, the clutch still engages at idle. Any suggestions on how to fix this is appreciated. I attached a short video so you can see the problem. Clutch appears to work great in neutral, but as soon as I put it in forward (or reverse), the clutch starts to engage and stall the engine.

Thank you

Greg

 

Hi, are there any Polaris tech's out there that can help me diagnose this problem and fix it? Thank you in advance for your help.

Greg