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Discussion Starter #1
I own a 2002 sportsman 500 HO. In the drive clutch is a brass washer that keeps wearing out. When it does the clutch will not disingage totally making it hard to shift. I have repaced this at least once per year since i have owned it. Is there any thing else i can do to?
 

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Hey welcome to the board!
 

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Discussion Starter #4
I am not sure but bought the machine new in 02 and have never changed the weights. I live at 13000 feet above sea level.
 

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Discussion Starter #5
This is the first forum for me but have been a atv rider for years. I also travel once a year on atv trips.
 

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weights might be worn out, it is one of the wear items the primary has, and it might be causing weird engagment of the clutch
 

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Check the weights for side play since they will eventually wear a “V” at the base of the clutch tower over time. This “V” will eventually result in the tip of the weight swinging off the roller and contacting the spider. When this happens the clutch hangs and the clutch shifts erratically. Flat rollers or flat spots in weights can occur. This condition also creates more wear on the sides of the weight bushing. If your weights run true you will wear the clutch bolt before wearing out the weight bushing.
this above quote was part of a maintence tip from the magizine snowest. there is almost no difference in the way a snowmoible clutch works and a atv clutch works as far as polaris goes, and this article is directly referring to polaris clutches....

typically at the shop often times when washer and bushings were being worn out one possible issue was worn out weights.

what part exactly is wearing out?

1 1520231 Clutch, Drive, One Way 1 Usage
2 7556202 Washer 1 Usage
3 5631119 Spacer 1 Usage
4 7541906 Nut, FLEXLOC 3 Usage
4 7541906 Nut, FLEXLOC 3 Usage
5 5431936 Button, Clutch, Stemless 6 Usage
5 5431936 Button, Clutch, Stemless 6 Usage
5 5431936 Button, Clutch, Stemless 6 Usage
5 5431936 Button, Clutch, Stemless 6 Usage
6 5020422 Pin, Roller 3 Usage
6 5020422 Pin, Roller 3 Usage
7 3585712 Bearing 1 Usage
8 7547130 Nut, Jam 1 Usage
9 3576510 Cover, Bearing 1 Usage
9 3576510 Cover, Bearing 1 Usage
10 7552801 Washer, Spring Lock 6 Usage
10 7552801 Washer, Spring Lock 6 Usage
11 7512176 Bolt 6 Usage
11 7512176 Bolt 6 Usage
12 7041157 Spring, Clutch 1 Usage
12 7041157 Spring, Clutch 1 Usage
13 1321457 Roller and Bushing 3 Usage
13 1321457 Roller and Bushing 3 Usage
14 5430945 Washer, Multilube 6 Usage
14 5430945 Washer, Multilube 6 Usage
15 7512266 Bolt, Shoulder 3 Usage
15 7512266 Bolt, Shoulder 3 Usage
16 5632283 Weight, Shift, 10-WHF 3 Usage
16 5632283 Weight, Shift, 10-WHF 3 Usage
17 1321706 Asm., Drive Clutch, Braking (Incl. 1-11, 13-15,18)(AA)(AB)(AC)(AD)(AE) (Incl. 1-11, 13-15,18) 1 Usage
18 7556204 Washer 1 Usage
19 5210752 Spacer (.020") (.020") AR Usage
19 5242981 Spacer (.025") (.025") AR Usage
19 5210753 Spacer (.032") (.032") AR Usage
19 5210754 Spacer (.050") (.050") AR Usage
20 3576504 Bearing, Moveable, 1/2" 1 Usage
21 5430261 Bushing 1 Usage
22 5210748 Washer 1 Usage
23 7512566 Bolt 1 Usage
24 7575202 Washer 1 Usage
25 1321632 Asm., Drive Clutch (Incl. 4-6,10-16,19,20)(EB) (Incl. 4-6,10-16,19,20)(EB)
 

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Discussion Starter #8
Part#2 and part#3 of the drive clutch. These parts have been wearing out since it was new.(they repaced them once under warrenty) I thought this was just a wear item until i talked with several people that did not own the HO model and they have not had any issues with theres
 

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Discussion Starter #9
I just installed a new washer in it last weekend and I could not find anything worn in the weights or elsewhere. I have also checked clutch alignment but it also seems fine. I was hoping this was a common problem with the HO model.
 

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Ive had the same problem with my 02 sportsman 500, there is another gasket like washer did u replace that and have u tried a new belt
 

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Discussion Starter #11
Sorry it took so long to get back. I have been out of town. I have replaced the plastic washer every year when i change the bronze washer. I also replace the spacer #3. It has had two belts on it also. I think this is a common problem with this particular clutch. I know of a 2000 500 that has never had the clutch apart on it.
 

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I have the same probleme, I change mind 2 year ago and I didn't make much traveling and the clutch start to engage again and it hard to shift.
 

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Let me ask you this, what is you deflection set at? You should NOT be replacing these parts that often, unless your doing 3000 miles a year. Mines a 2001 sptmn500HO and its never had a clutch issue or worn anything. Of course mine has less than 1000 miles on it too. Usually when a clutch has worn parts ( any) it has high milage, like our sleds 5000+ miles or a very serious clutch problem. Been in an accident, a do it yourself clutch kit install. Bushings in the weights last a very long time.
Since the parts you have there are a part of the EBS, spider and movable sheave & shim, its possible your belt deflection is too tight and always spinning this while at idle under pressure when it shouldn't. Your belt shouldn't move at all at idle. So if it spins you have to adjust your 2ndary to increase deflection. Another possibility but unlikely is a broken or severly sacked out primary spring. Unlikely, with that very weak blue spring. I think its like a 36lber. Oh also a very work sheave bushing or cover bushing. If thats the case a new clutch is the best solution. If you can post some pics, for better diagnosis.

I know of many of these same clutches with no problems like this at all.
 

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clutch problems

I have a 2012 Polaris sportsman 500 with 500 miles on it. the fourwheeler was running great and then the belt started slipping in high. I ordered a new Polaris belt and when I took the old one off they were both the same width. the old belt had been hot but it certainly wasn't worn out. I cleaned the clutches and put the new one on. no change I have checked the motor and trans mounts and their both good. I have looked this up on line and there is 2 possible belts that work on this modle but their is no appreciable difference in size. I'm stumped any ideas would help.

also I took it to a Polaris dealer and the first thing they wanted to do was change the clutches but I ran the machine setting on jack stands and the clutched seem to work fine.
 
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