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I have a 99 zr600. last year i had to rebuild my clutch because the spider striped and the clutch was spinning freely. i did everything it said to do in the manual and and now probally only 600miles later i have the same prob. Any ideas on why this is happening would help.
 

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Does the whole clutch spin on the end of the engine? If so, then try a new clutch bolt for the clutch.

The taper is what actually locks on the clutch, not the bolt, you can actually take the bolt out once seated, but it is not recomended.

If the clutch is still coming off the taper, then the torque spec needs to be double checked, and inspect the end of the crank for marring that would not allot a proper seat on the taper.

If all checks OK, check crankshaft runout on the PTO end, and check TDC with a timing wheel on the engine, there may be a chance the engine is out of balance and is shaking the clutch off.
 

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What he is saying is that the spider is stripping the threads off it. The clutch seats fine on the shaft and doesn't spin. The spider which is locked on by the big nut keeps stripping out causing the clutch end to free spin. I worked on it this weekend and All I can think is that the spider and nut aren't being properly torqued to the clutch. Anybody else see this happen?

matt
 

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What he is saying is that the spider is stripping the threads off it. The clutch seats fine on the shaft and doesn't spin. The spider which is locked on by the big nut keeps stripping out causing the clutch end to free spin. I worked on it this weekend and All I can think is that the spider and nut aren't being properly torqued to the clutch. Anybody else see this happen?

matt[/b]
Make sure you use loctite green on the spider and nut. The torque spec for the jam nut is 85 ft lbs.
This amount of torque and green loctite should hold it together. The clutches come from the factory with the spider shaft threads completely coated with loctite green. I have a very hard time getting the spider off without using an oxy-acetylene torch, heating the entire underside of it thoroughly.
I bought a clutch off ebay last year and ran it on my ZL600 this season for a couple hundred miles. Last weekend I noticed that the spider's jam nut had spun off and was jangling around on the shaft. In my case, the spider was still tight on the clutch.

I hope this helps!
Jeff
 
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