2000 Sportsman 500 Primary Clutch issue - Polaris ATV Forum
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post #1 of 13 (permalink) Old 05-19-2019, 04:20 AM Thread Starter
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2000 Sportsman 500 Primary Clutch issue

My primary clutch was completely shot so I purchased a cheap aftermarket unit (a mistake) and there is too much gap between the belt (new OEM belt) and the sheaves. I havenít measured the gap accurately but itís probably between 0.125Ē to 0.200Ē. The clutch engages late as you can imagine. I took this unit to the local dealer and after spending the $120 shop rate, they said it couldnít be reduced. Am I missing something? Iím considering just starting over and looking for a new OEM drive clutch but Iím having trouble finding them online (maybe due to age). Anyone know of a good source for OEM primary clutch (EBS) for 2000 Sportsman model? Or a good aftermarket source that actually works with OEM belts? Any help is appreciated.
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post #2 of 13 (permalink) Old 05-19-2019, 06:48 AM
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What clutch did it have originally?
EBS or non-EBS? Does it have the grooved one-way bearing in the center or no bearing at all? (top pic or bottom?)
What aftermarket clutch did you buy?
EBS or non-EBS?
Does the new clutch have a one-way or two-way bearing?
What belt number are you trying to use?

You probably just need a different belt to fit the clutch you now have but you'll have to give us some more info.
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post #3 of 13 (permalink) Old 05-19-2019, 07:22 AM Thread Starter
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The part number on the clutch that i see is 5630727-02. Yes, it is EBS, has the grooved, one way bearing. Using belt 3211077. Not sure of the brand. I believe it is Chinese.
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post #4 of 13 (permalink) Old 05-19-2019, 07:32 AM Thread Starter
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There is no brand on the new clutch... Bought it from ebay (https://www.ebay.com/itm/273038083101) (Seller Caltric). The listing stated it would fit my unit. Is late engagement a common problem with aftermarket clutches? Iíve also read that possibly using the spring from the old clutch may help and that the spring in the new unit is too strong. If so, would I need to change out the weights as well to match the spring?
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post #5 of 13 (permalink) Old 05-19-2019, 08:06 AM
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That's the problem, 3211077 is a non-EBS belt. Its way too loose.
You need 3211069. That's the EBS belt with grooves in it to match the clutch grooves.

https://www.ebay.com/itm/TWO-New-Pol...UAAOSwPa1cqLA5
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post #6 of 13 (permalink) Old 05-19-2019, 08:10 AM
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If the shop you took it to couldn't figure that one out, you need to take your business elsewhere.
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post #7 of 13 (permalink) Old 05-19-2019, 08:10 AM Thread Starter
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Well thatís good to know. I guess itís always had the wrong belt on it since iíve had it. Thank you
I had the dealer look at this new clutch and belt....you would think they would mention that.
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post #8 of 13 (permalink) Old 05-19-2019, 08:58 AM Thread Starter
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Assuming the correct belt is the same width as the one i have, i will still have the gap issue with the sheaves. This will cause delayed response with the clutch. Thoughts?
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post #9 of 13 (permalink) Old 05-19-2019, 09:16 AM
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The belt you have is too LONG. Non-EBS belts are much looser since they don't have a bearing to run on in the center of the primary. When the sheaves of the primary start to close, they have to close a LOT before grabbing the belt. Its supposed to have some play on the sides of the belt or it would rub/creep all the time.
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post #10 of 13 (permalink) Old 05-19-2019, 09:25 AM Thread Starter
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Ok. I will try the new belt.
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