Need to Kick a Mule.

George2615 · Apr 8, 2019

I haven't bought one yet but these places seem to have the best price for the manual.
1996 - 2013 Polaris 400 450 500 Sportsman Clymer ATV Service Repair Maint Manual

Polaris ATV Repair Manuals

Diggin It · Apr 9, 2019

Got the belt and got it on without too much trouble. Started machine and the belt turns while at idle. Not sure it's supposed to do that. Started machine (in Neutral), dropped into Reverse and it stalled. Repeat, same thing.

Feeling is that the clutch rusted into place on the shaft and isn't sliding in/out freely. Hit it with some PB Blaster Penetrant, but I'm not sure how much (if any) I can bang/tap/thunk on the assembly to try and free it. Will let it sit for a while and try again if anybody cares to chime in.

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Diggin It · Apr 9, 2019

Got it freed up. It'll move in and out now with throttle changes But as soon as you try to go into any gear, it'll stall. You cannot get into motion at all. Even taking the throttle adjustment screw on the carb down to a low idle, same thing.

There's got to be some sort of adjustment I'm missing.

George2615 · Apr 9, 2019

Now that you have it (the centrifugal part) freed up have you tried starting it in neutral and have someone push you on the ATV then put it in gear and drive it around. Maybe the clutch disc is stuck and driving around may free it up. Just a guess here.

Diggin It · Apr 16, 2019

I've had it running and driving around for a while, but it still has issues. Main thing is overheating and hard to start. Seems the corn gas sitting in it for years mucked up a few things. Stuff seems to do more damage than good. Waiting for a few parts in shipment to see what happens next.