Good Day Gentlemen. I searched as many posts I could find on this topic till I thought my eyes were gonna bleed. After all the research I am still left with the same questions.

Background - Bought a used quad this past December (an '05 Sportsman 500 HO/LE) knowing it had some issues but got a very good deal on it. Brought it into a shop in Calgary to assess a creeping issue and another problem. They suggested that I "replace" the primary clutch (and most likely the secondary as well) with a brand new assembly. The sheaves on the old primary were said to have a couple of cracks in them making a rebuild or the installation of a clutch kit impractical. The secondary was 'presumed' to be in as bad a shape as the primary.

I had heard that installing the primary from a newer ('06 and up) Sportsman 800 was a good upgrade. So, my question are as follows:

1. Can I install the primary from the SP 800 from 2006-2009? Or are there certain years and models that are not compatable? I still want the EBS feature. Does anyone have the model #'s that would be compatable?
2. Will I need to match a corresponding secondary that is compatable with the 800 primary?
3. I expect that an 800 belt would be in order as well. Correct?
4. If I get a new primary that is blank, do I need any special tools to put the new spring in?

Any advice or suggestions anyone has on the subject I would be glad to listen to them. Anyone with a good used one, I would entertain a making a deal with as well.

Thanks in advance,

Mike in Calgary
2005 Polaris Sportsman HO/LE
2002 Polaris Xpedition 425

you can use the 800 clutch but you will have to change the weights & springs not sure about the secondary helix though.it is common for those older clutches to overheat & crack the newer one has a smaller one way bearing with a lower gear ratio.you might be better to buy the clutch kit i will send you a pm.