I just changed mine for the first time any wanted to know if was normal to have to sand the buttons down to get the spider assm. to slide back into the clutch ? seemed odd to me but it was the only way it would go back together and it is still quite tight.

 

Now I know someone out there has changed clutch buttons or rebuilt a primary clutch before, how about some help for a Polaris newbie, I can help anyone with a Ski-doo clutch problem as a trade off.

 

I have a set on order. After I replace them, I'll let you know how they fit. My sp500 is making a ticking sound like an engine knock but it's coming from the clutch area not the engine. The primary clutch buttons are the noisemaker, I suspect.
Will let you know.

SurferSam

 

I have replaced a few on sleds and I never had to sand them. You are loading up the helix when you put the clutch back together I hope or you might be replacing those buttons again real soon. If your not sure what I'm talking about maybe talk to your dealer, Because there needs to be a load on the spring and helix when you put it together.

 

It's the primary clutch in question, the EBS secondary is a roller type, no spring wind up, I found the problem, I was given the wrong buttons, atv buttons are different than the ones for a sled, the atv buttons fit loose in the spider and have a rubber cushion on the back side of them, I never noticed when I took it apart because the old buttons all fell out on the floor, I just figured they were wasted and the guy sold me buttons for a sled clutch, the atv buttons cost more too, $5.00 each, thanks to all who replied.

 

How did you get the clutch spider apart? did you have a special tool?

 

Oh yes, I had to buy a holding fixture and a special wrench made to take the spider off and the lock nut, cost me $87.95, I don't know how you could take it apart and not ruin anything without it, I'll get my money back on the tools I have 2 people already that want me to rebuild their clutches for them.

 

You bet, The first thing I done not long after buying my first used Polaris was to buy all the clutch tools and the big honkin service manual. It always pays to know all you can and of course, have the right tools. I have a box full of all kind of primary and secondary springs,a box of weights, extra roller helixes,cool head chambers, and all kinds of other stuff just from a few years of testing,tuning and changing. I would hate to add all of that stuff up. YIKES!!!!! LOL Bubba