01 sportsman 500 clutch / shift issue

I have an '01 sportsman 500 ebs ho with 400 miles on it. It has been flawless over the years and because I do not trail ride it, it sits alot.

The problem is that it is very hard to go into high gear (it grinds, then clunks into it).

Recently, it will creep forward at idle. I have turned down the idle and it still does it.

Any suggestions?

I am sure that all the pulling and plowing I have done with it is the cause, then that's why I bought it. Pull the race car around the paddock, towing tool boxes, and plowing snow in the winter.

Thanks,
Doogie

ok, hopefully someone can shed some information on the belt. I just took it off and it measures 1.115 or close to an inch + 1/8th. Anyone have experience looking at these belts / measuring and knowing when to change it? The belt looks fine for the abuse it has taken, no glazing or broken pieces.

Thanks,

Doogie (yes, very new to working on these machines) I have been fortunate to just turn the key and ride it.

Haven't had to replace a belt on mine (2004), but being as yours is a 2001, if it has never been changed, and you have it off, I would go ahead and replace it. Just for curiousity, I would measure the new one and compare it to the old one, and keep the measurement recorded somewhere for next time you are wondering.
As to the problem at hand, it doesn't sound like a belt issue, but more of a clutch engagement issue. Something, possibly the clutch itself is not disengaging. Can't be for sure without looking at it, but I would suspect the issue to be the clutch itself.

Thanks Mike,

I think that you are right, just rotating the engine by hand, the belt is pulling, I would think that it would be rotating free. Yes, I am guilty of not doing proper maintenance. I'll get a new belt. Any thoughts on how to tell if the clutch needs attn? I certainly have the tools, equipment from my race car shop, just lookin' for some data.

Thanks much,
Doug

thanks Mike,

Off to the place that takes money for parts.

Doogie

Really can't think of anything that would make any sense as far as looking at the clutch to know if it is bad. It just sounds like that would be the likely area of concer given your explanation of what is going on.

Mike,

The dealer said that it might be the bushing(s) one brass/other plastic that the clutch slides on. The belt looked and sized just like the new one (without the new car smell of course). Because buying and or building the pullers etc are more than I want, it's going to get to spend some time at the dealer. Which of course the Kawie 750 and the sporty 800 are just looking to be traded up for. any thoughts on the two?

Thanks,
Doug

I drool every time I walk by a Polaris 800, but both would be nice bikes.

i had 2002 500 h.o. and it done the same thing with around 400 miles on it . it was the bushings that you are talking about but it wasnt very expensive. goodluck

Thanks sportsman 06,

It's good to get support here on technical issues, of course reading and exploring this site makes me want to get out and ride and of course spend more money on upgrading.

Do it because you can!

Doogie

Let us know if the bushings take care of yours. This could be helfpul information for others later.

That is, if you fix it instead of trading it, LOL.

Thanks to all for your input, it was the bushings in the primary clutch. The dealer fixed it and shimmed both clutches for 145 bucks. This site is great for information, photos, perspectives and problem identification/ solving. Keep up the great work everyone!

Now, do I trade up for a rhino 660? Going to test this weekend.

Doug

Just drove my sportsman 500, and because the clutches were shimmed and the bushings replaced, it drives better than it did when I picked it up new. I was amazed at the amount of input to get it to steer it when backing up. It was the pre-load on the drive system from the clutches pulling when they should be dis-engaged at idle. The steering is light and precise (like it should be).

I mention this because some others have written about tough steering on similar models. Because I don't have exact knowledge about cvt clutches (and little passion about finding out) I hope this can help others.

I didn't equate steering effort with clutches, now it makes sense.

the dealer was very impressive in how I gave them a open check to fix whatever needed attention, they fixed the clutches, replaced the belt (under warranty) and adjusted the throttle cable.

anyone interested in a '02 sportsman with 412 miles in excellent shape? (plow/winch included) The dealer stated that they would back up any questions on its condition.

Doogie