Here is my problem. I tuned up both of my clutches this week. I cleaned both and replaced both springs. On the primary I replace cam weight bushings and pins. I took it to my dealer to have the spider removed and rebuilt. When he gave it back to me he said it was a tad sticky and would be fine when I ran it. Well after I installed them, they engage after hitting the gas and stay engaged. The belt keeps turning at idle. I tried 3 different belts, even a worn one. The deflection is fine (1/16 over the top of the driven). Everthing else is the same. I plan on calling my dealer later today, but thought I woul dtry my snowmobile world friends first. Thanks.

When you say they engage and stay engaged, do you mean the primary is staying squeezed together and not returning to the full open possition? Is this sled sitting on the ground, or lifted on the stand?

I know I just bought a new uncalibrated clutch for my 800, because most said to just buy a new one, rather than spend all the money on rebuilding the old and after installing my wts and springs in the new clutch etc. The spider was a little tight at the top mostly due to the buttons. But I can't imagine with as much spring force as there is that it wouldn't return.

Your Deflection is not the amount of belt sticking up above the driven. That is basically telling you that the sheaves/backspacing are adjusted correctly. Deflection is actully the amount the belt moves up and down between the clutches. I can't remember the amount. Might want to check clutch alignment. THis is one that I am not to sure on how to do.
Will be soon. Cause I need to check mine.
Hope this helps a little.
Give us a little more info too.

One more thing, Did you reassemble the driven properly with the preload on the spring? I don't think that's going to make your track keep spinning though.
Sounds more like the drive clutch issue.

I called my dealer yesterday he said he would bet the farm I overtightened the weight pins and cover bolts. Last night I retorqued everthing and she is fine now! All we need is snow now!

Originally posted by BLUE ZL600 EFI@Nov 19 2004, 07:16 AM
I called my dealer yesterday he said he would bet the farm I overtightened the weight pins and cover bolts. Last night I retorqued everthing and she is fine now! All we need is snow now!
365201


I don't understand. How can you overtighten the wt. pins, or the cover for that matter. The wt pins are shoulder bolts. They will only go so far. Plus, even then, you would have to compress the entire casting around the wts.
Same deal with the cover. That cover would be next to impossible to change any dimesions or anything without stripping threads I would think. To be honest. I don't now, and never have used a torque wrench on any of those bolts, except for the bolt to the crank that holds the clutch on.
just my two cents. I have done many a wt bushings etc and never had an issue.

I think by overtightening the bolts you jam the weights and they don't return when you let off the gas. The cover has to be loosened to allow the the clutch to relax while you loosen the weight pins. Both are around 5 foot lbs. Waaaay less then what I did upon reassembly.

Originally posted by BLUE ZL600 EFI@Nov 19 2004, 10:27 AM
I think by overtightening the bolts you jam the weights and they don't return when you let off the gas. The cover has to be loosened to allow the the clutch to relax while you loosen the weight pins. Both are around 5 foot lbs. Waaaay less then what I did upon reassembly.
365257


I guess as a check I always move the wt back and forth after I tighten the pin, and before I put the cover on. I have to admit, I think I'm overtorqueing mine as well. But Haven't had any problems. No stripped threads either.