My 1987 Indy 400 clutch has a broken roller and a worn weight arm. How do I rebuild this clutch and what tools would I need? Dennis Kirk has a kit for $34 and on page 338 it shows a jam nut driver and a spider tool. Do I need both of these, or do I need more tools besides a clutch puller? I have never done this before, so any tips you have on rebuilding a clutch would be most helpful.
Thanks Doug

I just had my 88' clutch rebuilt with new weights, primary spring, and a rebuild kit from Wahlracing.com (the cheapest place). I would recommend taking it to a sled shop and have them do it. Well worth the extra money i think.

I just bought all the tools to rebuild a primary clutch with parts and a 3/4 inch breaker bar and pipe on the end of it and a sturdy bench, it ended up costing me about $250.00 with the parts to pull the clutch apart I purchased from Chopper City Sports in Fridley Minnesota, I also bought a torch wrench that would go up to 250 ft pds because you need to torch the spider to 200 ft pounds and the jam nut to 235 ft pounds. I just did my first complete rebuild and it turned out great.

Originally posted by DougMN@Dec 20 2003, 12:24 AM
My 1987 Indy 400 clutch has a broken roller and a worn weight arm. How do I rebuild this clutch and what tools would I need? Dennis Kirk has a kit for $34 and on page 338 it shows a jam nut driver and a spider tool. Do I need both of these, or do I need more tools besides a clutch puller? I have never done this before, so any tips you have on rebuilding a clutch would be most helpful.
Thanks Doug
To get the roller out you have to unbolt the jam nut and spider. These require both of the tools you mention (unless you have one of the rare clutches that don't have a jam nut) plus a clutch holder and clutch puller.

There are a few different clutch holders out there. At the time I was rebuilding my first clutch (many years ago) I couldnt' find a reasonable priced holder, so I made one on a lathe, basically matching the crank taper with the threaded center. On the non machined end I milled a couple of flats so it could be held in a vice. I'm still using it. One advantage the taper style is they will work on many different clutches (Cat, Polaris, and I believe Yamaha - Rotax uses a different taper).

So the answer - both tools plus the holder and puller.

Steve

Thank for the replies,do I need a special tool to drive out the roller pins,Doug.

I've never used any special tools for them (don't know if they even exist).

I agree with customindy400 - better let the shop take care of it and have the job done right. I have rebuilt clutches, but you need to have all the neccessary tools in order to do it correctly. In your case - take it to the dealer or a shop. WL.