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Old 03-08-2011, 08:18 AM   #1
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02 ZR800 driven/secondary clutch problems

Alright so this weekend racked up the KM on my zr. Begining of Sunday everytime I pin it it would almost sound like the track was skipping and wouldnt grab traction but the track was tight and wasn't skipping... Went for a ride and i could hear the clutches howling... On the lake I pull over because a chunk of belt comes flying out. Pop the hood and see the rollers are all melted down and te helix has 2 teeth broken off. 60 KM away I limp it back somehow with about half a belt and a fraction of the helix still tehre.

So I picked up a new helix and the 3 rollers and the 2 "bearings" that go inthe clutch, there not much of bearings but more of sleeves. I read somewhere that there are bushings in the secondary but the fiche doesnt show them. Can someone give me a hand as to where these bearings go? I read some people double up the bearings on 1 side but they didnt clarify which side. I think the side closest to the tunnel lost the bearing because it was chilling on the jackshaft when I removed the driven clutch so I'm hoping thats what caused this catastrophe.
Thanks guys btw i'm new to the site... Long time sledder from ontario
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Old 03-08-2011, 08:48 AM   #2
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One fits in the chaincase and the other directly behind the driven clutch. When you have the chaincase apart you may as well check the chain and top sprocket. Seldom does a bottom sprocket wear out, but the top sprocket on high horse sleds takes a beating because it is so small.
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Old 03-08-2011, 09:09 AM   #3
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Sprokets are good on the sled... Had something to do with the secondary. The bearings you are talkign about are on the jackshaft. Im talking about teh driven clutch bearings part number 2 in the diagram
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Old 03-08-2011, 09:25 AM   #4
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1 goes in the roller cover and 1 in the movable sheave. you will need a bushing driver to put those in. If it snapped the end off the tips on the helix watch when you put it together and see how far out on the tips the rollers are. a lot of those helixes lost the tips when they rode out to far.
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Old 03-08-2011, 09:37 AM   #5
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would i be able to get away using a long socket and a press?? I read that some people double up on the bearings there any idea which side they do that on?
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Old 03-08-2011, 09:49 AM   #6
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The problem with a socket or any other flat surface is you have no inner support and if it is real tight you smash the bearings before they seat. Check with a local auto repair shop. They may have a bushing driver and will put them in for you cheap. Find a piece of pipe or socket that will fit inside tight and drive the old bushings out yourself.
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Old 03-08-2011, 10:11 AM   #7
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I'm still a bit confused as to where the bushing closest to the engine goes. I figure it goes on the shaft but how deep? I know the bearing on the outside is still on there so I know where it goes it sits on the shaft under the spring
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Old 03-08-2011, 10:18 AM   #8
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I dont thnk we are on the same page. Are you talking drive clutch or driven clutch bushings. On the drive clutch they go on the movable sheave and cover plate. The came goes for the driven clutch. You will need a spider tool to change the bushing on the front movable. Also, on your sled if I am not mistaken you cannot change the bushing on the drive clutch. I am sure the bushings they sold you are for the driven clutch. Go to alpha sports and look up your sled. Go to the driven clutch and look for no. 2 part and you will see where they go.

Last edited by Mike R; 03-08-2011 at 10:21 AM.
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Old 03-08-2011, 10:27 AM   #9
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i posted a link up top part number 2 is the bearings/bushings I bought. Its for the secondary clutch or driven clutch
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Old 03-08-2011, 01:05 PM   #10
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also what you can try is clean your secondary clutch sheaves and make sure your bushings are good and were they ride are clean. if your busings are worn out it could cause the secondary clutch to stick open and make the sled slow and make it boggy
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