02 mxz chassis with rer uses the bar #529 035 530 , which leaves 35.5 mm-37 mm,NOW with a regular sec using the same bar i have the same measurement from the fixed side of the bar but the clutch is still 1.5 mm from the notches on the bar. my question i guess would be do i use the 35.5 from the fixed sheave side of the sec or use the bar notches?

not sure about how your tool is made? if you use a 3/8" flatbar clamped tight in the secondary, the distance from the outside of the flatbar to the outside of the carb side primary sheave should be set to your belt width. Add another mm to the exhaust side if you like for twist and run the torque stop touching but not tight.

I am not exactly sure what the measurment we are talking about, but a RER secondary is smaller diamater than a Formula clutch.

I line the clutches up by using a square bar and letting the spring in the secondary hold it for me. Then I have a measurement from the outside of my bar to the side of the primary closest to the engine (measure with 4" calipers) both in the front and the rear.

I have gotten my clutches lined up perfectly in this manner for my RER, then did the same thing with a Formula clutch. With a black ice helix in it I had to add .045 spacer before installing the formula.

Your C to C distance is also different. You need to add 1MM. Or in my case the difference in O.D.'s was .085 (2.16MM). Divide that by 2 and get .0425 (1.079MM).

Hope this is what you were after.

Keith

I'm a clutch alignment phreek....but sometimes I uhh....
...use the small socket thingy and run it between the two clutches.
If you can take that small socket thingy with the holes on either end, I think they're 10mm & 13mm ended....if you can run them between the clutches with them just touching then that's good enough for me....

hahahahahaha....

.....im not kidding. :devil: