I bought a clutch kit from PSI and installed it in my '99 ZRT 800. The kit consisted of 58 gram weights, orange primary spring, red secondary spring, and a 60-40 helix. The problem is acceleration didn't feel any different and i lost 10 mph off top speed, so i took out the 60-40 helix and put the stock 57-50 back in and accelertion pulled more and i got my 10mph back on top speed. Now i noticed on the 60-40 helix the rollers only traveled half the distance i don't know if it's supose to do that or not. I was gonna try another helix other than 57-50, but don't know what to get. My riding style I want is the fastest accel i can get without loosing top speed maybe gain some top speed. Anyone have some ideas on what i should do? thanks for the help it just might same me some $$$ finding the right set-up :D

Oh come on where's all the clutching masters? LOL I'm trying learn clutches since that's my last thing to learn about sleds. hehehe I was thinking If i added more weight to the primary would that help the rollers go farther down the 60-40 helix if i put it back in? I hear the 60-40 is better, but need to figure out why it's not traveling the full helix.

I guess the big question would be what rpm did it pull before,and what part of the curve did the clutch kit effect??Eg,i have a mach z set up similar to what you have,mine pulls hardest when lugged real heavy coming out of the hole(clutch to max torque)then let it raise in rpm as you pick up speed,ending with the tach planted at max hp.Sometimes it is easier to dial in with a straight angle helix(sorry im not up on specific cat combos)That helix seems like quite a spread in angles(some guys like this)My experience is to let it pull the steepest helix that it will pull and still have a descent back shift.I usually just take a box of clutch and gears to a radar run and have at her,let the radar gun be your dyno.Dont be surprised if the rpm that shows best on the radar gun is way diffenent than the dyno sheets for your pipes or porting.

I for one have no idea on what spring tensions are, but if it is a Cat 2ndary Red, then you might want to stiffen it up or even go to a Goodwin silver (stiffer). Also, are they Polaris weights, or Cat weights (base heavy or tip heavy). I assume they are tip heavy Cat style weights. If so, try about a 64 Polaris weight.

That sled should pull more weight. Sounds like it might not be shifting out for some reason either. Many Cat sleds will have the roller cover bottom on the helix, even stock, so look for that.

The springs are from Cutler what ever they maybe for tension and i'm guessing the weights are polaris cause the package said polaris industries.

I Think your problem lies in the helix...A 60-40??? I can't see how that helix would work..thats a big shift...what rpm's are you running???My buddy had a 99ZRT 800 and it was a dog??we tried a 60-50 from Dalton..that didn't work so we tried a 57-49 with 60gram weights secondary spring in the second tightest hole(#4).It ran better but still not great...make sure all the updates have been done it...there's a #### load..everything from clutching,carbraters,muffler..and i think airbox..

I had all my updates done and besides I'm running mostly after market stuff. Let me tell ya with the stuff i had done it really woke it up i just need some edvice on clutching what i have. and if i remember my rpms were 4900-8800 rpms not 100% sure but it's close.

I bought a clutch kit from PSI and installed it in my '99 ZRT 800.
The kit consisted of:

58grams
orange primary
red secondary spring
60-40 helix.

The problem:
...acceleration didn't feel any different and i lost 10 mph off top speed.
took out the 60-40 helix and put the stock 57-50 back in and acceleration pulled more and i got my 10mph back on top speed. Now i noticed on the 60-40 helix the rollers only traveled half the distance i don't know if it's suppose to do that or not.

This to me is wonderful information that you give. :D

That 60-40 helix I would use in nearly anything. I even use 60-35 helix. Just a matter of flyweight mass, and/or placement of mass on composite arms.

Questions:
What were your rpms like when you use kit?
...underrev?...overrev?...maybe slight overrev & hard to tell?
Did you test the temperature of your secondary after some exercises?


Greenman writes:
I was thinking If i added more weight to the primary would that help the rollers go farther down the 60-40 helix if i put it back in?

Mmmm...yes possibly to a point of your scenario/exercise.
I say to a point because depending on what answers you have for my two questions will depend on my next scenario.

I wish you had an adjustable weight like a heavy hitter or thundershift kit to perform one test. Not necessary but it would learn you two details about weight instead of just one with the possibility you mention above.

My opinion don't count this kit out yet. Your engine may have better fitness and compression than the workhorse that this kit was built upon. This being said I believe that it is just a flyweight amount issue.

heh heh...Ugh, me say big spread helix angle means midrange that make paleface eyes bulge and have screaming top end...

Hi Dynamo^Joe to answer you ?'s my sled did over rev towards top end. I can't remember actually rpm's, but accel seemed ok up until top end then it sounded in fact it was over reving and i was hardly reaching my top speed. I remeber feeling the primary and secondary i can't remeber, but i believe they were very hot to the touch. Should i beable to touch them? Yeah i wish i had the thunder shift thats why i need some help so I ain't spending $$$ and getting no where. What i want is a set up that will make the sled pull harder then it ever did before with out top end loss.

GreenMan]......my sled did over rev towards top end.

From experience I would have to say this is great then. If you are starting to climb in rpms then it should be because the secondary is resisting the push from the primary. The flyweight mass is not enough to overcome the angle progressing to a lower angle, therefore the rpms should climb.
This being said then you would tend to think the secondary is going to be cool temperatures, mind you I do not know what cool temperatures for this sled is. It is an 800 so there is a substantial amount of torque and the primary will pull that belt thru the secondary sheaves...slipping.
But, seeing the rpms rise as you get to greater speeds, then you would tend to think that the sheaves are gripping the belt quite hard putting the clamp on.

GreenMan]...I can't remember actually rpm's, but accel seemed ok up until top end then it sounded in fact it was over revving and i was hardly reaching my top speed.

You further indicated looking at the helix seeing the mark down the roller/button path was not going down that much. The secondary is resisting the push from the primary.
How to overcome I would think is to add more flyweight.
If you are happy with the shift character, the backshift, upshift....especially the response in the midrange rpms, then I would add more flyweight to create more push.

GreenMan]...I remeber feeling the primary and secondary i can't remeber, but i believe they were very hot to the touch.

Being an 800 I would tend to think so as much more than a 440 or 600 in the same exercise.

GreenMan]...Should I be able to touch them?

Touching hand on metal:
130 deg F = 5 seconds or more
140 deg F = 4 seconds to "ouch"
150 deg F = 2 seconds to "ouch"
160 deg F = 1 second to BLISTER!

I believe it would be nice to have temps of 140 or less. I bet with more flyweight you will grip the belt harder and less slip will happen in the primary. The belt temperature should be less, the secondary should be less. This all with flyweights having enough mass that will pull right on a straight shift at required rpm.

GreenMan]...What i want is a set up that will make the sled pull harder then it ever did before with out top end loss.

Just my opinion but I do believe that when you throw some more flyweight in, you will push the rpms down and the performance will increase.

OK thanks Dynamo^Joe that's the info i was looking for ;) :thumbsup:

My friend is having the same problem and we can't figure out. We don't know much about clutching either, but what is flyweight mass, is that the primary weights? Or is it the secondary spring pressure or in wrong position hole?

What is your gear ratio?
What is the rpm you want to run at?
What is the mph you are hoping for?