Need some help on most economical way to fix a Polaris 400 Sportsman clutch situation. A buddy gave me a 2002 that was not running and partially disassembled by an independent shop. They wanted ~ $2K to fix it and it wasn't worth that to him so he gave it to me. I got the engine running, and replaced all the fluids, but they had taken the clutches off the machine. This is the first time I've ever dealt with a Polaris or belt drive machine, so I obviously have some learning to do.
I took them by the local Polaris dealer and they pointed out the radial cracks in the primary clutch - so obviously I needed a new primary. This is a going to be a play toy for around the property, so I didn't want to sink a bunch of money into it. I ordered a Parts Ace Primary non-EBS Clutch and was going to rebuild the secondary clutch just to be safe. Unfortunately, I did not realize until I disassembled the secondary clutch that this is apparently an EBS set-up - as there is no tabbed spring and there are rollers instead of buttons. In looking at the primary, the center shaft is ribbed, which is apparently another key indicator of an EBS clutch (according to EPI).
Parts Ace doesn't make an EBS clutch for the 400, and I can't seem to find any other sources, although Parts Ace and others do make an EBS replacement clutch for a 500 Sportsman.
Here's where I need some help:
1. Is a Sportsman 500 EBS clutch interchangeable with a 400 EBS clutch? The on-line Polaris parts catalogs don't even show an option for an EBS clutch, so I have no idea what the part number for that would be. If they were interchangeable, then I could get the Parts Ace 500 EBS clutch and use it?
2. Could I run the Parts Ace Sportsman 400 non EBS Primary with the Factory EBS secondary clutch? I realize I would not have EBS, but I'm not sure if this is really going to be a big deal? Also, not sure if the two will align properly?
3. What is the proper belt for an EBS-equipped 400? The existing belt that was on the machine was Polaris PN 3211077, which is the same one the local dealer gave me when I asked for a replacement belt - but at the time I did not know it had EBS and I understand that EBS takes a different belt.
Just trying to figure out the most economical way to get this machine operational again. I'm a little hesitant to buy a brand new OEM EBS primary, for two reasons: 1) I don't know the part number to order or the cost and 2) I'm not sure what else might be wrong with the machine and I don't want to sink a bunch of money into a brand new EBS primary and the find out there's a problem with the secondary or other things and suddenly I'm committed to $1500 worth of parts. I've already replaced a few low $ items (starter, pull rope), but I noticed it has a ripped CV boot in the front and seems like the shocks are kind of bouncy - so I suspect there's some other hidden things that need fixing.
Looking for advice or ideas from you guys who are much more knowledgeable on Polaris stuff than I am.
Thanks, John