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.
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
