Replacing Primary Spring

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BlueRider17

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Dec 10, 2004
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Maine
I'm going to replace the primary spring on a 97 XTC 500. I'm planning on doing it on the sled. I need to mark the cover and take out the small bolts on the cover, do I need to take the nut that holds the primary off too?

Thanks
 

I dont believe you have to remove that nut unless you want to remove the shieves.

BTW, the inside of your clutch cover has an "x" on it that matches up with an "x" on the spider to keep everything in balance.
 
it is actually a bolt that holds the clutch onto the crank, and yes you need to take it out to get the cover off, as well as the 6 small bolts. Line the X's up when you put it back together, or mark yourself externally, your choice.
 
to replace the spring you do not need to remove the big bolt, only the 6 small ones that hold the cover. You can then replcae the spring and make sure to allign the X on the cover to the one on the clutch.
I just did mine 2 weeks ago, replaced spring and added weight, never removed the big bolt.
 
Be careful to not put undue stress on the cover. Tighten the cover bolts in a repeating sequence a couple turns at a time. Push in on the cover to take the pressure off the spring so you don't strip the first few threads.
 
BlueRider17 said:
I'm going to replace the primary spring on a 97 XTC 500. I'm planning on doing it on the sled. I need to mark the cover and take out the small bolts on the cover, do I need to take the nut that holds the primary off too?

Thanks
Click to expand...

No, to change the primary spring, all you need to do is remove the cover by removing the 6 cover bolts. Make sure it's aligned with the same orientation when you put it back on - I mark the cover and make a matching mark with a magic marker on the clutch. In order to make it easier to get the cover back on, I bough three 2-inch long 8mm bolts as "cheater" bolts and tighten them down sequentially to get the cover down to the point where the original bolts will engage, remove the cheater bolts then tighten the originals down sequentially and torque them to specs.

You don't have to remove the big bolt or remove the clutch.
 
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