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Discussion Starter #1
Hello all; looking for some insight from the gurus. Reading on here most suggest just buying a new clutch; however I am in Canada and they are prohibitively expensive here...

Sled is a 96 Zr580. Has about 5,000 miles and the primary clutch is pretty rough. I can't see any cracks. As far as I am aware it has NEVER been rebuilt. Has a yellow spring; green stripe.

Rollers look rough and are no longer in contact with the weights. The weights have a crescent groove out of them.

I am thinking a full rebuild is in order? No idea what all those parts are worth.

New clutch is $712; plus tax = $805. Surely I can rebuild for less than that?


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When i did mine, the weights were $20 each. I think the pins like $20 for the three. I believe any more than those items and the spring, you have to remove the spider. If you dont have the right tools, its cost prohibitive. Alpha Sports has the tools, but they are $300. That spider requires close to 200 ft lbs of torque. I might be off on that a bit, but its a lot.


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Discussion Starter #3
Thanks for the reply; I don't have the tools but a chum of mine does....I priced out the parts including spider from local dealer microfiche and it's more than the clutch new!! I can get a comet for 400 or so plus tax then need weights and spring.


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There was just a 9 post on craigslist last week here in Syracuse for $125. I can get you the info if you need it.


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Just my 2cents but from experience, buying a used clutch will most likely be a money pit and a headache when you find that a lot of those years there's bushing that aren't available. The comet option is most cost effective in the long run.
 

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Discussion Starter #9
Thanks for the tips. Looks like the comet is cheaper to rebuild too. It's not like I am racing the damn thing; I just like to get out and go for a ride. I think the comet would be fine.


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Purchasing anything from the US from Canada right now is costly due to the dollar for the OP. Royal Distributing has comet EXP 108 clutches at reasonable prices new. They ship free anything over $80
 

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Dont quote me on this, but can you not get a new factory cat clutch from ebay.. Uncalibrated but under 400 to your door? All youd have to do is swap in your springs and weights.. Like said, i could be wrong.
 

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You buy what "looks like" a good deal for a used one..Then you find out that certain years you can't get bushings for it. Then if you're fussy, you'll find out soon enough that you "got what you paid for".
 

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Dont quote me on this, but can you not get a new factory cat clutch from ebay.. Uncalibrated but under 400 to your door? All youd have to do is swap in your springs and weights.. Like said, i could be wrong.
Yes you can but… the op is from Canada. Taxes and exchange make it costly to buy anything out of the US right now. An uncalibrated clutch is $711.00 before taxes to buy in Canada. Thats just going by a 96 580 efi ett online parts fiche.
 

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So...I know nothing about engines except my mechanic is taking me for a ride...I guess I need a primary clutch, but instead of him getting one I've decided to look nyself. I found a fairly cheap clutch for a 1995 zrt 600, but I have a 1996 zrt 600. Is it compatible? Please help
 

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I just went through this and the problem I ran into is mine the inner bushing were gone and couldn't be replaced I was lucky enough to find a very good used one changed my spring and back on the trail but I looked all over and made calls all around to find the clutch
 
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