Good morning,

I'm a newbie to both this forum and doing anything other than changing plugs in my machine.
I am finally getting over my fear of tinkering. I have a 99 zr 600 carb. Changed main jets to
330 (simple!) & removed secondary clutch for cleaning. Noticed some play when belt removed.
Bearings ok, seems to be as if stub shaft/driveshaft worn, but no indication of wear except a lot
of powdery rust. Is this normal? Also, when I re-assembled, (with all shims & washers in their
original positions) there is a small amount of play in & out on the shaft. Is there a minimum
amount of play required here or should everything be tight?
I would like to buy the Clymer manual but it only goes up to 1998 model year. Is there much
difference between 98 & 99?

TIA

There should be some axial float after bolt is tightened back up, don't know exact spec, I would say about 1/16" is normal. Also there is always some rotational slop due to the key/keyway clearance. Be sure to check bushing on inside of clutch, they need replaced occasionally.

I allways let the secondary clutch float a little, I just got the 00,01,02 cat service manuals the other day they say to put anti-sieze on the shaft after putting it back on, I just used greese. 330 main jets? Check plug color and piston wash after a wide-open run. :)

Forget the Clymer manual and go to your dealer and ask for a service manual for you particular sled, I just got mine(same sled as yours) for I think $37.00 , lots of pic.s and great info.
Oh yea , heres the part #- 1999 ZR 500/600 Carb. service manual-2255-938, make sure thats right but thats what mine says.
Good Luck, Todd

I've got the service manual for my 99 ZR and it helps a lot. Especially for answering questions like this. From what I remember the float spec is 1.5mm on the secondary clutch. My wifes ZL has more float than that and I haven't had a problem with it yet. I wouldn't be concerned!