I was riding one day on my Polaris and all of a sudden it wouldn't really move at all and I could hear the belt hitting the clutch cover and it seemed like it was really loose. I took it apart and figured the belt was bad it was glazed on the sides and I thought maybe it was stretched, so I ordered an oem Polaris belt and put it on so the numbers were facing the clutch cover and it still is very loose and won't move a whole lot and rubs. I have no clue how to tell if it's something in the clutch or if the sheaves are grooved, I am new to this stuff and it would be awesome if i could get some help. I'll show pictures if anyone needs to see, thanks!

 

If you can push the front clutch in and it still retracts out,the problem could be in the rear clutch.If you want to check into clutches best to have the manual if you haven't worked on one before. Special tools needed on the front clutch but the rear clutch can be pulled off and taken apart. The manual has good instructions and pics on this. Here's a good one for 5 bucks.2004 Polaris Sportsman 400 Service Manual PDF Download

 

sorry if this is a dumb question but do I just push the primary clutch in and it should retract out? And shouldn't it spin freely left and right? What kind of special tools do you need I may have them

 

Primary(drive)clutch pushes in and out,secondary(driven) clutch,one sheath spins and opens and retracts back in. Could be problems with either one or both and possibly time to look over both of them for button wear,etc. Bushings in the front clutch can wear also causing problems,ramp buttons in the rar can wear and do the same thing. Needs a clutch puller to remove the drive clutch and a spider tool to separate it. Here's a simple video on how clutches work on an ebs system.Yours is a non ebs,but principle is the same.

 

How expensive could that be? If I have little experience wrenching on a clutch could I do it myself?

 

Parts aren't that expensive especially for the rear clutch ramp buttons,but the front clutch again takes a spider tool to tear one apart to be able to replace bushings,guide buttons, etc. Get the manual and you can do the rear clutch with no problems. Look at this video on rebuilding a drive clutch.It's an ebs clutch with a one way bearing which yours doesn't have,but the process is still the same. If in doubt you could always pull it off and take it in to have it rebuilt if needed.

 

My secondary clutch spins with the primary when it is just idling in park with no gas, why is this happening?

 

The first video was on an ebs type clutch system,if working right the rear clutch won't turn at an idle.This video is on a non ebs clutch on a Scrambler. You'll see that the rear clutch will turn.Common for these to have the rear clutch turning along with the front. Still doesn't mean that ramp buttons,guide buttons don't need to be looked at and replaced if needed.