2004.5 sportsman clutch

[atles618]

I am having a problem with the primary cluch not opening up at idle and the atv stalls out . I pulled of clutch and found a lot of cracks on outer flange can i get it welded and machined or do i have to replace it or is there something else that i am missing.

[klevister]

Go ahead and replace the clutch. Look on ebay and see if you can find the clutch off a 2005 or newer. These have a smaller one way bearing on it, so it actually gives it a lower starting point on take off. You can really tell a difference with the clutch swap, i have done it on my 04.5 500 HO.

[Kevcules]

Clutches are very expensive but if yours is worn too bad , then replace it with a new one IMO. My 01 has a few small 1/4" cracks also. I decided to try to save it by drilling a 1mm hole at the end of the crack , just like a windshield. If the crack gets any larger then its going to be replaced with a new one. The dealer wants $550 for the primary assembly without weights and shoulder bolts, but they only want $50 more for a complete clutch "kit". This includes a new primary assembly , a new secondary assembly , and a new belt. Unless you can find a good price on a good condition used clutch then buy new and it should last a long time.

Good Luck

Kevin