2001 Sportsman clutch engaging too soon?  Extremely difficult to shift - ATV Forums at ATV Rider Magazine ATV Rider

2001 Sportsman clutch engaging too soon? Extremely difficult to shift

  
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2001 Sportsman clutch engaging too soon? Extremely difficult to shift

 
Allred Allred
New User | Posts: 1 | Joined: 07/09
Posted: 07/02/09
06:41 PM

For the second time, my 2001 Sportsman 500 with 1300 miles total, is becoming very difficult to shift from from neutral to/from hi, low or reverse when the motor is running at normal idle speed.  When I do "jam" it into gear, the bike begins to move immediatly.  Using the brakes to keep it from moving, slows the motor to such a slow speed that it dies.  When the motor is off, shifting is easy.  I think the clutch is not dis-engaging (again)

When this happened the first time, the local shop said the drive clutch halves had grooves worn in them.  They replaced the whole drive clutch, $420 plus Labor, ouch!  They told me to use low gear more often, to prevent the belt from wearing a groove in the clutch halves when the motor is pulling a heavy load, such as driving onto a trailer, or up a steep incline.  I tried to follow their advise, but now, 300 or so miles later, the same problems are returning.  If I start the motor, I can't shift in or out of gear.  If I start in gear, the bike  wants to move even at low idle speed.  It is VERY difficult to shift when the motor is running.  If I brake to keep from moving the motor dies.  

Has anyone heard of the "grooved clutch surfaces" problem.  Is there something else I shouldl try?  Are Polaris PVT clutches really so easy to wear out?  

Thanks,  I hope to not have do another $400 plus labor repair!

Thanks,

Allred  

 
ATOMANT ATOMANT
New User | Posts: 43 | Joined: 06/09
Posted: 07/04/09
06:51 PM

You need to remove the clutch cover and watch whats happening. If the whole clutch is new then that cant be the problem. Perhaps its a broken motor mount causing a misalignment. Also make sure you have the correct belt installed.  

 

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