Secondary clutch disassembly

S

stubby

New member
Joined
Nov 10, 2003
Messages
28
Location
Macomb Township, Michigan
Is there anyway to take apart a secondary clutch without the fancy service tools? I can tell that this is a dangerous thing to try and disassemble without the right tools and/or knowledge. My 1994 Vmax 600 is eating belts and I removed the secondary and can tell that a bushing behind the helix is worn badly on one side. This is making it wobble. I wonder too if the busing under the spring should be replaced too? This sled only has about 1800 miles on it. I have noticed from the service/owners manuals that your supposed to move some of the washer/shims as the belt wears, does anyone really do this? I haven't and maybe that's why the bushing wore prematurely? I'm hoping this is an easy fix, I can get this back together and go riding in 3 weeks! Thanks in advance...!! :)
 
the secondary is the easiest....take the 3 nuts out of the helix slowly to releave the pressure, then push the helix in and remove them buy hand .....twist the helix out with the spring tention and then remove the sheaves....with the center bolt.
 
Well I don't have three bolts and I was advised not to try and take this apart without the proper tools....I have a circlip and the whole assembly has to be compressed to remove it. Found out that the bimetal bushing is shot and two of the plastic buttons are gone...I can't believe that I had to pay $50 for that bushing..these manufactures sure F us! Hopefully my VMAX 600 will get mileage now too! I was told that that was taking a ton of power to move that pulley with two bad buttons..will repost.
 
I have a 94 vmax 600 and you can take the secondary apart with no special tools.Have a buddy push down on the helix while you remove the circlip and washer(note which holes the spring is in).My bushing was also shot,paid 45.00 for it.
 
I just did mine, I just took a piece of threaded rod and put some washers on it to compress it, then took the clip off. then just loosened the nut on the rod to take it apart. Real easy, and real cheap.
 
Wow, never thought of the threaded rod idea, thanks! I took my clutch to a guy down the street who owns a Ski-Doo dealer ship and we went to high school together, he took it apart for me and reassembled for $25. Much better than the local Yamaha dealer that wanted $85...!!! Hope this helps my belts last longer! LOL...thanks guys...happy riding
 
There isn't that much spring pressure. What I do on the old style Yamaha secondaries is put it on the floor helix up, then I put my knee on the edge of the helix to take tension off so the circlip can be removed.
 
Thanks again for the tips, I guess being that I didn't see the secondary come apart at my friends shop, I just assumed that the helix is under great pressure and torque and didn't want to mess with it. I am very excitied about getting my clutch put back on (my machine is at my brother's house who lives about a half hour away). Plan on putting it all back together on Saturday morning and seein how it does. Going riding in Hulbert Michigan in a few weeks and hope to have my sled and my wife's, brother's and sister in law's all up there...all Yamahas! woo hoo...thanks all......! :)
 
Either Bender Racing or Maxximum Performance sells an oil-lite bronze or duralon bushing for the secondary for around $20. It lasts longer and is more efficient than the stock bushing. Too bad you had to settle for the stock set up. If your secondary is that bad, you should check your primary. The 600 twin engines were notorius for eating rollers and bushings in the primary. You could be loosing some performance there also, not to mention contributing to belt wear.
 
Thanks for the tip...I'll be sure and check that too. Hopefully it won't give me anymore problems for a while. The bushing that was removed didn't seem to be worn that badly, just those 3 plastic pieces. And two were gone. I put on a new Dayco Max belt and cleaned the primary and secondary surfaces that the belt rides on , and it seems to be doing great. Will post back after our trip...thanks again all!
 
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