[Joe B]

I've had my 96 sportsman 500 for a year or so now. Both the primary/secondary were completely worn out so I replaced them both. The primary was replaced with an new ebay Zoom Zoom clutch and the secondary CVTech model.
New polaris belt.

Top speed won't exceed 30mph. I removed the cover to watch the sheaves were moving correctly, they are, but only in low gear. In high gear, they only move 3/4 of the way.

Is my engine just tired? Runs fine but I wouldn't think it would have no top speed like this?

 

[Scrappy507]

You should be seeing top speeds around 45. I think the “zoom zoom” and “CVTech” brands are part of your issues. Are the old clutches actually worn down or do they just need a rebuild? How much did you pay for the eBay clutches?

 

[Joe B]

You should be seeing top speeds around 45. I think the “zoom zoom” and “CVTech” brands are part of your issues. Are the old clutches actually worn down or do they just need a rebuild? How much did you pay for the eBay clutches?

The Zoom Zoom primary clutch was $139. The CVTECH secondary was $261.

The originals were just so worn, they were well beyond rebuildable. I looked around for used polaris clutches but it was just a grab bag or someone else's junk. Thought I was doing better by buying new...

 

[Scrappy507]

Post up some pics of your old clutches so some of the more knowledgeable guys can take a look.

 

[latebird]

The POS Zoom Zoom clutch is the same quality as Zoom Zoom carbs - I remove and toss them routinely and install high quality (by Chinese standards) the $45-$60 Standard of Japan or KunFu carbs. For $100 to $120 I can install a new Mikuni VM carb and foe upwards of $200 a Dellorto carb. I would use a Comet clutch over any Chinese product and if it were my ATV, I would install a Polaris clutch.

But at the same time, I would be parting out a 96 instead of fixing it - that's just me.

 

[Joe B]

The POS Zoom Zoom clutch is the same quality as Zoom Zoom carbs - I remove and toss them routinely and install high quality (by Chinese standards) the $45-$60 Standard of Japan or KunFu carbs. For $100 to $120 I can install a new Mikuni VM carb and foe upwards of $200 a Dellorto carb. I would use a Comet clutch over any Chinese product and if it were my ATV, I would install a Polaris clutch.

But at the same time, I would be parting out a 96 instead of fixing it - that's just me.

I just got done installing the weights & spring off the original primary. No difference. I installed the original secondary and it didn't perform near as good as the CV Tech. I'm leaning towards my primary is the culprit, but maybe your right. Sell this one & buy a newer model

 

[bp405]

Zoom Zoom sounds like it's a Boom Boom waiting to happen, toss it!! CVTech is a legit clutch company!!! Buy a legit primary and go from there!!!!

 

[FPD218]

Zoom Zoom sounds like it's a Boom Boom waiting to happen, toss it!! CVTech is a legit clutch company!!! Buy a legit primary and go from there!!!!

You Should be on SNL tv