Both primary and secondary clutches on my 2004 Sportsman 600 Twin needed attention. I purchased the Sportsman with over 2500 hours and over 6500 miles. I knew going in that there were several areas that needed work, but the price paid reflected that.

I pulled the clutches off and ordered a rebuild kit for the secondary. I knew I could fabricate the special tool needed for that rebuild. I took the primary to the dealer since the cost of the tools needed for a rebuild far exceeded the one hour of shop time to install the parts to rebuild the primary.

Turned out that the primary had stress cracks in the sheaves so it was decision time. A factory clutch was just too costly to purchase for a quad with my kind of miles and hours and one I don’t use all that much so I went with a Comet clutch for less than half the price of factory.

Fast forward to the install. Everything went well, but I ended up with the common problem of creep and inability to shift when the quad is running. I already knew this was a good possibility since I’d been reading every post I could find on the Comet clutch.

I fiddled with the washer-like shims, and double checked the clutch alignment, but it became evident that was a dead end. I’d read several posts where it was suggested that you use a non EBS belt, but all of these particular Sportsman had EBS. I picked up a non EBS belt for a different Polaris quad that had the same basic dimensions and as bonus it was fractionally longer. When installing that one I knew it was going to be a bust, and it was…same problem…creep.

More searching got me nowhere so I call the folks at Comet. It was suggested I use a Comet belt, 300638C. I was even pointed to a supplier that had some in stock, beltpalace.com. This belt is slightly more narrow, as is the Comet clutch, and it was about 3/4 inch longer OD.

Popped it on, creep is gone, shifting while running is back as well. I’ll be monitoring it for wear over the next year, but I don’t anticipate any issues since the construction seemed as robust as the factory and the other belt, which I was able to just return since it saw no use beyond the 20 second trial in the garage.

Obviously the belt I needed and used might not be right for your model, but the procedure is solid. BTW, the number of the person in the know at Comet is 608 774 0481. The helpful guy at the beltpalace is at 317 519 9020.

Hope this helps when the next person comes along looking to install a Comet clutch.