Clutch pics & video, before and after cleaning affect

[Sam Zuehlke]

Looking for pics for the casting that is causing problems and the solution. Thanks guys .

 

[yukon yamaha]

I cant wait to see the casting problem and fix!

 

[cannondale27]

It's on the Secondary right where the towers from inner half go through the outer half. The towers are where Helix gets bolted too. The flash is on outer half and rubs the towers. Need to clean mine up if nobody beats me to it will take pics then.

 

[cannondale27]

Here.The flashing rubs the towers.

 

[TestMaster]

Thanks guys for the info it's always greatly and mean greatly appreciated!!!
Buddah if my wife ever found out the I put the clutches in the dishwasher I'd be castrated on the spot!!!lol

My wife's says I can use the dishwasher for clutches as long as it's her clutches. As she explaines it, it's her tool (dishwasher), and her clutches. I need to find my own solution, she has hers! LOL!!

 

[NOS-PRO]

Was out in the shop taking pictures of other things and mainly concentrating on getting the Phazer project back together. Brain fart.... DOH!!!

I will have a secondary taken apart tonight and really go step by step on what is causing the issue and how to remove the flash.

 

[yamamarc]

Was out in the shop taking pictures of other things and mainly concentrating on getting the Phazer project back together. Brain fart.... DOH!!!

I will have a secondary taken apart tonight and really go step by step on what is causing the issue and how to remove the flash.

 

[titanrcr]

Hey Terry!! thanks for the write up and video!!! When I installed my cotc kit my spider did not move freely at all like your video!! I thought it was just the tight tolerance of the bushing on the shaft. Thanks I will be doing a proper cleaning after seeing the thread! I've only ran 8jp belts from new but have all the proper shims to change to 8dn for next season! Any info of what to pay attention of in the secondary would be greatly appreciated??? do you guys use brake clean on your clutches?? Here is a pic to give you a idea of how much belt dust was accumulated with under 1000km
View attachment 107548

Are you sure that's not from your brake pads? Open your side panel and look for belt dust under the clutches on the belly pan and under your belt guard.

 

[NOS-PRO]

Hey guys n gals! Took some vids last night and also some pics of a secondary I have as a spare.

The secondary I did this with was not really that bad compared to others I have come across, so keep that in mind that there are much worse cases out there, but in the end it shows how to fix the problem

1- Take off belt
2- With the correct size wrench or socket, remove the secondary bolt
**NOTE** Some may want to take off the helix at this point to make it easier to control the spring pressure. This works well if by yourself. Key note is to make sure you watch where the spring is set at in which holes like mentioned in step 5.
3- When taking the seondary off, watch the backside of the secondary to make sure the washer on the shaft does not come with the secondary and gets lost. This washer keeps the secondary in-line with the primary and also protects the bearing.
4- With the secondary on a bench, remove the (3) 12mm nuts that hold the helix on (but keep some hand pressure on the helix so it doesn't come flying off)
5- While removing the helix, watch to see which holes the secondary spring is in. There is a #1,#2,#3 on the secondary sheave half and a #0,#3,#6,#9 on the helix. These numbers are how you set your secondary spring twist and are pretty important that you put them in the correct or same holes that the spring was in. Another thing to watch is how much the helix tension twists counter-clockwise.
6- With the helix and spring removed, separate the clutch halves.
7- The clutch sheave with the steel splined shaft will have 3 oval windows that the helix towers poke thru, these windows are where you will find the flash.
8- Remove casting line flash with a rat-tail file, air grinder or belt sander.
9- When finished removing flash, check clutch sheaves for cracks, burn or glazed areas (scotchbrite will get rid of glazed and burned areas) and clean the clutches from belt dust, filings and sanding grit before re-assembly.
10-Re-assemble clutch sheaves and install spring and helix. (Make sure that the drill points on the outer edge of the sheaves match up as these are when they balanced the clutch)
11- Install clutch on secondary shaft, torque bolt per spec. and install belt.

 

[NOS-PRO]

aquaticlaker sent me 2 videos which shows how his clutches are engaging and popping back freely after the cleaning.....but for the life of me I cannot save them to my phone so I will be sending them to my email and getting them loaded up.

 

[yamamarc]

Just want to say thank you for the detailed step by step instructions with pictures!! You rock Nos!!!

just wondering would it be easier to remove the helix and spring while the clutch is still on the machine?

 

[yamamarc]

Just want to say thank you for the detailed step by step instructions with pictures!! You rock Nos!!!

In your opinion is this the main reason for everyone's speed inconsistency from one to another

 

[NOS-PRO]

Just want to say thank you for the detailed step by step instructions with pictures!! You rock Nos!!!

just wondering would it be easier to remove the helix and spring while the clutch is still on the machine?

I would say it might be better to remove and install the helix on the machine

Just wanted to make sure whoever does this check....makes sure they watch where their spring is in which holes.

I will add a note to my instruction list

In your opinion is this the main reason for everyone's speed inconsistency from one to another

Some I have seen, yes....but can't really say for everyone. Some clutches are deburred/flash removed just fine and others are like WTF? But, in the cases I have seen, it has helped greatly with top speed, over-revving and inconsistant weight change results.

 

[aquaticlaker]

aquaticlaker sent me 2 videos which shows how his clutches are engaging and popping back freely after the cleaning.....but for the life of me I cannot save them to my phone so I will be sending them to my email and getting them loaded up.

I tried to upload the video here but, as you can see i failed!

 

[yamamarc]

tore my clutches apart and holly crap were they caked especially the pockets where the spider runs!! With 2000km on the machine I never thought it would be that dirty!! I did file the flashing even though it didn't seem to be interfering with the tower too much! The worst spots were at the end of the slots where it stopped the tower about 1/16" to the end.