[SteveCZ]

Well, since there is 3 inches of ice out here, I can't go riding, no snow to cool the sled..... so I waxed her up AGAIN (5th coat)..... goin through the engine bay, checking for the rotted out rubber intake boots and just an overall check of the engine.  Checked the primary, looked fine, then checked the rollers on the secondary, one is spinning freely, the other two don't move at all.... Is this a problem, and if so, is there an easy fix or should I just leave well enough alone?

Heres the sled info:
1999 ZL500 carb
2400 miles
Stock, except for 96 studs on center belt.

 

[zr580s rule]

it shouldn't be a problem as long as the rollers do not have flat spots in them from skidding across the helix instead of rolling like they are supposed to

 

[Winter_storm]

Ideally the helix should be pressing against all 3 rollers and none should spin freely.  Are the 2 rollers froze or just being pressed against by the helix??  You can check this by holding the outer side of the clutch sheave and turning the inner sheave.  This should rotate the rollers off the helix and with your third hand you should be able to spin all 3 rollers freely.  If they all 3 spin freely it means all 3 rollers aren't contacting the helix.  Not a crisis, but makes the clutch not as effecient as it should be.  Easy fix..  Remove the belt.  Remove the bolt holding the secondary on.  Remove the secondary.  Remove the 3 nuts holding the roller cover on.  remove the cover with the rollers.  Be sure to mark the cover and one of the towers so you put it back together in the same hole.  And mark the hole the end of the spring is in.  Take out the secondary spring.  Put the cover back on without the spring.  Now you should be able to easily open and close the clutch and see if all 3 rollers are rolling against the helix.   If not loosen the helix (allen head bolts) and reposition helix so that they do.  tighten the helix up. remove the roller cover reinstall the spring and put everything back together.

 

[Winter_storm]

Assembling the secondary without the spring also makes it simpler to check for full shift-out of the secondary.  Some clutches don't open all the way because the roller cover hits the bottom of the helix before the belt travels all the way to the bottom of the secondary resulting in missing out on a few extra MPH's.   Ohh and if the rollers are completely froze(don't spin), then like " ZR580'S RULE" said, it'll work fine, the plastic rollers will slide up and down the helix just like the plastic buttons on non-roller secondary's, it just wont shift as effeciently as it should.

 

[fast 600]

What can you do if your clutch touches the bottom of the helix?

 

[catrules2000]

The easiest thing to do is remove the Secondary clutch.  Now, get a Allen Wrench that is long enough to loosen the Helix where it is bolted on.  Take all three Allen Head Bolts and just break them loose.  This will allow the Helix to "Center" itself.  Now tighten it back up and put it back on.  Good luck!!!

 

[Winter_storm]

Some people are installing shims or washers between the secondary towers and the roller cover to get full shift out.  Also alot of the newer aftermarket helixes are deeper cut so it's not an issue.