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post #1 of 10 (permalink) Old 07-31-2012, 12:27 PM Thread Starter
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clutch buttons

Does anyone know what causes the clutch buttons to fail? I will be on my second set in a little over 2 months. I was just coasting down a power line when I got to the bottom I hit the gas and I noticed the machine wasn't sounding right. When I got to 20 mph it would not accelerate any further. Being I just had them replaced I knew what was wrong. Any advice would be greatly appreciated.
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post #2 of 10 (permalink) Old 07-31-2012, 12:45 PM
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When i replaced mine, i filed and emory clothed the helix and sheave until very smooth, kinda important to get all the gouges out.
If it rolled over(spring lost it's preload),Possibly your helix itself is too worn down .
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post #3 of 10 (permalink) Old 07-31-2012, 03:49 PM
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post #4 of 10 (permalink) Old 08-02-2012, 09:28 AM
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Helix never wears, they only get damaged. good idea to smooth out the ramps, but they all have to be perfectly even for smooth shifting. Hopefully they didn't put in new buttons with a damaged helix. severe bearing wear or a broken secondary spring can cause the sheaves to bang or ride very unevenly putting all the load on 1 button, once 1 goes the other 2 go fast. I don't suggest repairing rebuilding a secondary if its more than bushings or a helix. Replacing bushings just buys u more time. Miles? any sheave wear?

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post #5 of 10 (permalink) Old 08-02-2012, 11:58 AM Thread Starter
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post #6 of 10 (permalink) Old 08-03-2012, 04:39 PM
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i have a 98 sportsman 500 with 7k and wont go over 20. im hearing and reading about the clutch buttons, just one ? where are they, what r they and how hard are they to replace?
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post #7 of 10 (permalink) Old 08-03-2012, 05:13 PM
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Quote:
Originally Posted by sportsman010 View Post
i have a 98 sportsman 500 with 7k and wont go over 20. im hearing and reading about the clutch buttons, just one ? where are they, what r they and how hard are they to replace?
They are in the secondary, are what the helix "grabs" to make the bike move and are resonably easy to replace provided you have the tools needed to do it.

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post #8 of 10 (permalink) Old 08-03-2012, 10:07 PM
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The three buttons are a nylon type material,held in with torx type screws. The helix and the spring pressure are what holds this all together. If the spring isn't right it won't drive properly.

'96 Xplorer 300 Aftermarket CDI box, K&N filter, jet kit, reworked expansion chamber from dirt bike, 1" taller + 1" wider rear tires, dual wenches, Rack on rear/w cargo pac, polaris box on front, Mossy Oak cover on seat, back-up lights on rear, aux. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! Would love to find GURU style bumpers! By the way, I'm also a graduate of AMI with over 20 years of motorcycle mechanical experiance. New to quads, but the same basic engines. 2 stroke or 4 stroke!
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post #9 of 10 (permalink) Old 08-04-2012, 06:23 PM
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my ? is how do you remove the clutch buttons? is it simple to do or a real pain in the ass? and the clutch buttons are in the primary drive clutch right? any advise would be very helpful. Thanks.

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post #10 of 10 (permalink) Old 08-04-2012, 11:49 PM
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The buttons are in the rear clutch. Not hard to fix if all other parts are ok. There is a video on youtube showing how to do this, very informative. Give a yell if you need more help.

'96 Xplorer 300 Aftermarket CDI box, K&N filter, jet kit, reworked expansion chamber from dirt bike, 1" taller + 1" wider rear tires, dual wenches, Rack on rear/w cargo pac, polaris box on front, Mossy Oak cover on seat, back-up lights on rear, aux. power source for GPS,"Theft deturent's", hand protectors, new clutch springs coming! Would love to find GURU style bumpers! By the way, I'm also a graduate of AMI with over 20 years of motorcycle mechanical experiance. New to quads, but the same basic engines. 2 stroke or 4 stroke!
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