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Old 03-08-2011, 04:21 PM
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Changing the clutch buttons.

Changing the clutch buttons on a new to me 1998 Sportsman 500. This quad had been sitting and PO Could not get it running. I cleaned the carb and installed a missing caliper. Now it has brakes and runs but felt like no power. It would acell to 15 20 then fall on its face. I pulled the belt cover and pulled the driven clutch. Compressed the spring in a press removed the snap ring and wow. Clutch buttons are toast! Scratched the helix. I polished the helix and putting on new buttons now. My question is, it has a red spring and both ends were set at #2. Is this correct? How often should these buttons be changed? I guess I have 4 more to do.
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Last edited by 3 Polaris Atvs; 03-08-2011 at 08:49 PM.
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Old 03-08-2011, 04:55 PM
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Not sure if there is a set "time to change" on them. I have changed them many times on previous machines. One trick I can tell you is to put in your torx driver and tap it with a hammer to break loose any corrosion. Aluminum and metal tend to corrode together. I broke one off one time. The local polaris dealer had a junk bin that had a clutch half that was in good shape and gave me this tip. I also put anti seize on them to prevent this in the future. I take off my belt once a year just to check on them and the belt. If they need or are getting close I just replace them at that time. The buttons are one of the most overlooked parts on an ATV.
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Old 03-08-2011, 06:43 PM
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Clutch buttons are changed. What a difference! It will now pull all the way to 50 mph. Problem is it still drags. If you crank the throttle it holds back like timing is retarder. If you let off a little it will accelerate slowly. Kinda feels like exhaust is plugged. Is this a tell tale sign of the flat cam? No backfire just doggy. My same year Scrambler will run a way from this one. Think my 250 will also.
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1995 Scrambler 400 4x4
2000 Trailblazer 250 2x4
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Old 08-03-2013, 09:09 AM
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Clutch buttons are on the list for me then i guess. Mine is doing that exact thing. It has tons of power till it shifts at about 5-10 mph then nothing.. dead to the world. It will speed up but will take about a week to get there lol.
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Old 08-03-2013, 05:24 PM
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What hole you put the spring in depends on elevation, what is he elevation where you live? I set them at #1 on the clutch and #2 on the helix, but I live at 5000 ft.
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Old 05-31-2014, 03:43 PM
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anyone have pics of the button location and how to swap them out?
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Old 05-31-2014, 04:22 PM
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They are inside the secondary clutch and held in with a screw. Very easy to swap.
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Old 05-31-2014, 04:38 PM
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Do I have to remove the snap ring, helix and everything else in order to get to them?
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Old 05-31-2014, 04:52 PM
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Yes you do
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Old 05-31-2014, 05:32 PM
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Not sure if it matters; but I just flipped mine over as only 1 side was worn & they seem to be as good as new.
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