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Clutch problems. Chasing a ghost right now.

3.4K views 13 replies 10 participants last post by  skinnyclimber  
#1 ·
SLED: 1995 EXT 580 EFI

SYMPTOMS: Secondary wont engage (open) over 3000rpm and engine bogs down.

TROUBLESHOOTING TO DATE: Shimmed for proper belt tension, new sheeve bearings and buttons spring is good and in 3rd hole. Tensioned track. Checked jack shaft dimension against clutch dimension (in tolerance). Plugs are new, gas is fresh. Jack shaft bearings are good. Clutch alignment is within tolerance.

When I run the sled on the stand it runs up perfect, both clutches engage at the right RPM engine runs smooth. When I take it out and put load on it it bogs down as soon as the secondary should engage. Doesn't matter how I work the throttle.

At the end of my rope. :Bangin:
 
#3 ·
Have you checked the primary? Usually if it boogs that`s a sign that it`s allowing it to open the secondary too easily too soon. If the secondary wasn`t opening it would just cause the engine to over rev like crazy. I would check for a broken primary spring and if it`s not that then do what greg was suggesting and check your jets, but if it runs fine on the stand, but bogs when under a load it would almost have to be either in the clutching or driveline somewhere. There is the possibility of jetting, but unlikely.
 
#5 ·
Sounds more like a motor issue...could be clutching related but the sled will act like you just described when there is a motor issue. Check compression. Also, when the stator is going bad...it'll do the same thing. Check you stator ohms. Specs are 450 and 45.
 
#8 ·
On that sled you need to check the air temp sensor and water temp sensor resistance also. a bad sensor will cause that issue also. If you know the temp of the air and the sled has sat and is ambient, do the resistance tests and then we can give the resistance it should be.
 
#10 ·
check the tps sensor it could be going bad check by touchin the far left and middle pins by pulling the plug on the rightside of the throttle body and get the ohm read out at idle then at wot i have a service manual i just spent three days combing over fixing my 97 580
 
#12 ·
i have the same sled and i found out that the piston broke a peice of piston skirt and made a small hole on the bottom of the crank case, it would start and the bog down, also the comp was good becouse the rings were good to seal
 
#13 ·
Check the fuel pressure with a gauge on the supply (left) side of the fuel rail. The pressure should be 36 psi and must not drop when you flip the throttle or try to accelerate. If it drops a lot, the fuel pump is probably bad in the tank. This happened to me after the tank was drained and stored all summer with the pump dry. It wrecked the seals inside the pump and it got progressively worse running until it would not do 30 mph. The fuel pressure would drop to 19 psi when the throttle was opened. A very, very expensive mistake.

BP
 
#14 ·
The solution:

My coil was burned up. The primary clutch had be thrashed by a previous owner and broke the balancing weights off so the clutch had eaten itself up pretty bad. Both the fuel pump and fuel pressure regulator were broken as well.

Runs like a top now.