'96 Sportsman 500 - replacing clutch spring and weights - Polaris ATV Forum
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post #1 of 3 (permalink) Old 08-12-2019, 04:41 AM Thread Starter
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'96 Sportsman 500 - replacing clutch spring and weights

I need to swap out the weights and clutch spring on my 1996 Sportsman 500.

I was reading up on how to change it and looking at the clutch and it seems like I can replace just the weights and spring without fully removing the clutch. Is that possible? I don't really want to spend the money on the clutch tool if I don't have to.

If I have to pull the clutch, where is a good place to buy the clutch removal tool?
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post #2 of 3 (permalink) Old 08-12-2019, 05:36 AM
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Yes, you can do all the work with the clutch on the machine. I have done it several times. You will want the main spring, weights and don't forget the shafts that the weights ride on. They get worn and should be replaced too

Mark the cover of the clutch so it goes back in the same place, they say it's balanced that way. All you need to replace the weights and shafts is an allen wrench and I think 10mm socket works best.

Mine: 2018 Sportsman 850SP - 26" Bear Claw HTRs on OEM steel wheels(I really don't like the Aluminum ones)
Polaris Hand warmers, Mirrors.
Hers: 2019 Sportsman 450. 26" Bear Claw HTRs on Moose 427X Wheels.

2007 Sportsman 500 EFI, Polaris Winch, 25" Bear Claws QSC Clutch Kit, Hand Warmers
2001 Magnum 325 MOSE 12" rear wheel conversion. 25" Sedona Coyote tires
2017 Polaris Ranger 1000XP - Roof and front glass
2018 Kawasaki KLR650
2001 Magnum 325 Warn winch and Moose 60" plow-Sent to Daughter and Son-In-Law since his blew up
SOLD 2004 Sportsman 600 Twin
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post #3 of 3 (permalink) Old 08-12-2019, 07:07 AM Thread Starter
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Perfect. I was hoping that was the case. I did find some videos online where people made their on DIY pullers that I can make if needed.

I was planning on replacing the bolts as well since I have to remove them anyways.
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