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Old 12-26-2010, 05:07 PM   #1
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Sled: 2000 Zr 600 EFI
2000 zr 600 clutch adjustment needed

I need a little information about adjusting the stock clutch on my 00 zr 600 efi. the engine has less than 100 miles on the rebuild and wasnt properly set after the re-install. sometimes it seems to engage right but 90% of the time the sled just doesnt accelerate right. most of the time it feels like like an automatic car with a bad transmission mount, it shifts and has like a jerk. Im very mechanically inclined but I know next to nothing about these clutches. Im wondering what I can do, if anything, externally before digging into the insides. thanks alot!
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Old 12-26-2010, 06:57 PM   #2
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I should probably note also, it engages usually around 3500 rpm, has purple primary spring and yellow secondary spring. I have yet to see it over 7000 rpm at around 70 mph... top speed so far and took a while to get up there
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Old 12-26-2010, 11:10 PM   #3
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So I took the secondary apart, but the issue may be only the space between pulleys, I would assume I shouldn't have been able to pull the belt off without loosening something or at the very least walking it off the secondary pulley, it pulled off with a few back and forth motions.... would this cause the issue? I would understand the top speed and low rpm but shouldnt it engage at a higher rpm also? in order to make the belt tighter do I just tighten the spot at the motor mount bushing? I noticed also that the rollers that go against the spike part of the secondary are worn down a bit.... I guess I'm more confused now than before, some symptoms contradict whats happening. the belt is very slightly rounded inward in the center of the outer facing area too. I looked up the springs, they seem to be stock as well as the rest of the components.... I'm lost, any help appreciated.
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Old 12-27-2010, 09:17 AM   #4
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Sled: 11 TZ1 Turbo,02 800 CCE-136,07 F5,05 Sab
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FWIW,
Try the search, there are many threads with similar problems.
You may have to do some reading but you should get an idea or two!
From your observations,
I'd think your sec. spring is shot, I've found the A/C sec's a b*t*h to get opened to take the belt off.
Also, check the primary spider, to see if the weights are digging into it.
The bushings in the weights wear down and go off centre as the clutch moves inward.
If you don't address this....MAJOR $$$$$!
These bushings last 2500-3000 miles.
Cat has a re-build kit.
This should get you started.
Good Luck!
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Old 12-27-2010, 04:37 PM   #5
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Thank you, I did try searching many times but I didnt have any luck. I'm going to try to take the clutches off today, let them sit over night with pb blaster. last night I took the outer three nuts off the retension ring on the secondary. after I take them off I'm going to check the center to center of the shafts, I took the belt off the secondary side first and pulled right off, the primary was open all the way.
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Old 12-27-2010, 05:57 PM   #6
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I guess my clutches aren't 100% stock after all, the primary back says zrt 600 which I would guess is probably the same, the weights however, from what info I can find online are 60 gram polaris weights. They say 10-60 on them. The engine should have no problem pulling those right? Stock is supposed to be 48.5 grams. the secondary still refuses to budge. I'm going to run to Kaukauna and get the cam rollers and replace those right away and maybe the second dose of pb blaster will work by the time I get back.
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Old 12-27-2010, 06:30 PM   #7
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Not necessarily 60's.
I'll have to pull out my book to x-reference them.
Got to head out right now,
Will let u know later 2nite.
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Old 12-27-2010, 08:41 PM   #8
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appreciated!
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Old 12-27-2010, 10:33 PM   #9
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Just looked it up.
Those are 60 gram.
Stock are listed as 52's. depending on altitude 0-5k.
The stock engagement is 4500. Those 60's will have brought that down to 3500.
That secondary needs to come off.
If it is stuck, you may have to remove the whole shaft and press it off.
I'm thinking the secondary spring is shot, if you took the belt off that easily.
Just did it with my 500.
Be ware of the alum. spacer out , don't try to press against it.
Also, check that primary spider.
Make sure the weights are not rubbing on it.
I'm not a clutch expert by any means, there are guys on here who have forgotten more than I'll ever know.
These are just some things I've run into.
Anything else, I'll help when I can.
Kim
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Old 12-27-2010, 10:35 PM   #10
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ATV: '96 Big Bear
Forgot to mention,
I bought the Aaen Clutch Tuning book a while ago.
Great info in it.
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