Primary Clutch Stub Shaft Question

[Ray Reed]

OK, I have search hundreds of posts.

Question, I purchased new/used 2009 Nytro XTX this fall. I replaced secondary bearings on jack shaft and drive bearings. I also replaced donuts with copper like you said. I had my girl reassembled and started her up tonight and saw sparks coming from primary between clutch and engine. The sparks stopped after about 2 minutes. Is his the clutch?

I researched the stub shaft. Has anyone seen this? I hope I do not need to pull primary. I am ready to put her on the trailer and wait for snow, but I do not want to get 50 miles down the trail and have a breakdown.

The slop/axial play seems normal from what I read.

Any help would be helpful

 

[Beenba]

if the sparks were flying when the engine was idling, then its safe to rule out the clutch itself.

Sounds like you need to pull the primary and get the stub shaft out, bearing is likely gone.
I'm not sure if you can get at the 4 12mm bolt heads with the clutch on there. Would be a huge PITA even if you can. I would just pull primary.

Look at my "official clutch rattle thread" to see how i got the stub shaft out.

 

[canoehead]

You ran it for 2 minutes while sparks where flying?

 

[Ray Reed]

The sparks were when I rev it up the engine and now there are no sparks. I was trying to understand if the sparks were from the clutch sitting all summer or from the stub bearing. I have started and ran it up to 30 MPH on lift several times and there is no more sparks. I am not sure if it was from summer rust or bearing. I hate to tear into the stub shaft if it is unnecessary. You know any time you start something there is always unexpected problems (broken bolts). I assume from the lack of responses people have not seen this. Probably because they have not seen sparks.

I know sparks are NEVER good but wanted to check with everyone to see if they are normal at start of season. I assume I have a bad bearing and axial play is causing the sparks. I would rather deal with this now than waste time in riding season.

Any one have a bearing hub they want to sell....something with LT 3000 miles on it. I have 7000 on the machine and purchased it used. Motor sounds great and now oil burning

 

[Ray Reed]

BTW. I just got a nice tank bag for X-Mas....I don't want to worry about carrying a sleeping bag in it

 

[kviper]

Pulling the stub shaft is not that big of a deal if you have a clutch puller and a slide hammer. I just pulled mine. I pulled the clutch and threaded the clutch bolt back in to the shaft,removed the four bolt's holding the shaft/bearing housing, rigged up a way to hook the slide hammer to the bolt and it came a little hard at first but it came out. I can't imagine where spark's could come from on the clutch? I guess I would pull it to make sure the bearing/seal are good so you don't damage anything farther.

 

[canoehead]

You might want to look at the main electrical harness which runs behind the primary just above the stub shaft. It's a known problem especially on the 09's. It rubs on a casting nub and am just wondering if that is your source of sparks.

 

[Ray Reed]

Great suggestion. I will pull the clutch next week to give more visibility. These are the things I want to know to look for. Thanks Caneohead.

I have a clutch puller from a 1990 Exciter that looks like it will match my clutch. 18mm 1.5 threads. It would be great if it works!

I'd rather do this stuff while it is off sled and not packed full of snow. The guy I bought the sled said there was nothing needed, but the donuts were non-existant so I think he just rode the heck out of it....which is what I plan to do. Just want to get the obvious issues taken care of. I have blocked the tunnel, added insulation to the relay, added extra insulation to the main power line from batter (runs across the oil tank), new bearing in jack and drive shaft, replaced drive cog since the bolt was broken off and I couldn't remove it and did the oil change in engine and chain case.

I like to work on sleds (preventive) but want to be done. The stub shaft is it I hope. I am not planning anyting else unless you guys say I should.

O.....I rebuilt the shock with Monster Performance.

 

[kviper]

Will be interesting to see what you find!

 

[Beenba]

You might want to look at the main electrical harness which runs behind the primary just above the stub shaft. It's a known problem especially on the 09's. It rubs on a casting nub and am just wondering if that is your source of sparks.

Good Point...check and fix this while your in there.

 

[kviper]

Anythings possible but it would surprise me to have sparks from harness for that long and not have electrical problems showing up. The harness is a good thing to check while clutch is off any way. Are you sure the tin shield under the clutches isn't wrinkled up from blowing a belt and rubbing on the clutch?

 

[Ray Reed]

Pulled clutch today. The bearing was missing half of the ball bearings. I guess I found the source of my sparks. I got the hub pulled out....very easy. I was able to use my slap hammer I bought for removing hyfax. I could not believe the end screwed into the stub shaft....what are the chances!

I am glad I took the extra time to pull the clutch.

 

[kviper]

Where did the rest of the ball bearings go?

 

[sorenson1610]

I had the same thing happen to my stub shaft, wobbled like a bitch and half the ball bearings were gone. I could hear them getting ground up but couldn't figure it out, though it was ice from the track. I had some of the ball bearings stuck in the clutch fins lol Easy fix actual