Clutch wont disengage - Polaris ATV Forum
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post #1 of 6 (permalink) Old 07-16-2019, 12:39 AM Thread Starter
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Clutch wont disengage

I need a little input.
I have an 04 Sportsman 500 HO, I was trail riding and came to a washout, I went into it slowly and the front tires both hit the washout, I gave it some gas but it just spun (a few revolutions, I didnt just sit and spin) the tires so I backed up and hit it at an angle and walked right through it.
After this happened the clutch wont disengage, goes fine down the trail but when I brake to a stop it kills the engine. If I start it in gear giving it a little gas it will go fine until the tires stop turning and it dies again.
I assume this is related to the clutch, before I tear it apart I was hoping I could get some input on what to look for.
Thanks in advance... Roll on..
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post #2 of 6 (permalink) Old 07-16-2019, 03:21 AM
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Pull the clutch cover to see if the belt is actually staying engaged.

2011 Sportsman® 800 EFI
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post #3 of 6 (permalink) Old 07-16-2019, 04:52 AM
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Got to get the clutch cover off - check the clutch movement - it may simply need cleaned and lubed - it might need some new parts to operate properly

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post #4 of 6 (permalink) Old 07-16-2019, 09:12 AM
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I just had the same machine in a few weeks ago with the same problem. You'll probably need to be looking for a new or good used clutch. I'd be safe in guessing that everything in yours is worn out if its never been serviced up to now.
Brass washer #2 is probably completely gone and the one-way #1 has worn down the spacer #3 so that the sheaves overtraveled too far inward when you spun it briefly. This caused one or more of the fly weights #16 who's rollers, bushings and bolts #'s 13, 14 & 15 are also worn out and flopping around to let one of the weights get off the roller and stuck on the shaft holding the clutch closed tight on the belt. You'd likely also find upon taking it apart that the moveable sheave will have hairline cracks around its base. Even if you could rebuild it, the parts would cost more than a good used or after market new clutch. You'd also have to buy or build the special tools to do it with or pay someone that already has the tools to do it.
Bottom line... you need a clutch or clutches and belt.
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post #5 of 6 (permalink) Old 07-21-2019, 09:26 AM
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Quote:
Originally Posted by latebird View Post
Got to get the clutch cover off - check the clutch movement - it may simply need cleaned and lubed - it might need some new parts to operate properly
Hi dont want to steal this but what do you lub in the clutch?
I thought every component was supposed to be dry, so no rubber dust attaches to it. Should the weights be lubed, and if they do what is supposed to be lubed with?
Thanking you in avance.

Last edited by Poveiro; 07-21-2019 at 09:37 AM.
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post #6 of 6 (permalink) Old 07-21-2019, 12:45 PM
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Quote:
Originally Posted by Poveiro View Post
Quote:
Originally Posted by latebird View Post
Got to get the clutch cover off - check the clutch movement - it may simply need cleaned and lubed - it might need some new parts to operate properly
Hi dont want to steal this but what do you lub in the clutch?
I thought every component was supposed to be dry, so no rubber dust attaches to it. Should the weights be lubed, and if they do what is supposed to be lubed with?
Thanking you in avance.
There are two "camps" on this topic. To lube or not to lube!!! If it is to lube then there is a dry type lubricant used as to not attract clutch "dust". I am in the no lube camp. Keep the clutches clean and they'll perform flawlessly.

2011 Sportsman® 800 EFI
GURU front brush guard
GURU rear brush guard
Polaris front lock n ride cargo box
Polaris rear rack extender
Warn RT 3.0 winch w/amsteel synthetic line
Viper aluminum haus fairlead
Polaris front spring adjusters
Ricochet a-arm guards
Ricochet full frame skid plate
ITP T-7 beadlock 14" w/OMF inner rim guards
Maxxis big horn 2.0 26x9 front
Maxxis big horn 2.0 26x11 rear
QSC clutch kit
EPI HD springs front n rear
ODI rogue 130mm grips
Ultraseal commercial grade tire sealant (front)
Highlifter tire sealant (rear)
CTEK 3300 battery maintainer
added 7 zerks
beefed up wiring harness
OGIO rear bag
ROTOPAX 1gal. + 2gal. gasoline can
Jccapri bushing kit
Kolpin Over Fenders
Rigid Industries E-Series 10" flood
Walker Evans struts
NGK Iridium's (2,500 miles on Champion's and they looked great!)
Odyssey Extreme battery PC545

2018 Sportsman® 570-T
2019 Aluma® A8818
2020 Outlander® 1000R XXC (on order, ETA mid-Sept)
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