trouble getting my secondary and /or clutch alignment tool to slide on the jackshaft

bluemonster1

bluemonster1

LIFE MEMBER ONLY ONCE!!!
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Dec 30, 2005
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Howden ,Manitoba,Canada
So today was an normal day like any other...until I decided to get the SXR600 running and into the garage and do maintenance on it.Actually had the secondary in the house,so took it to the shed where the 600 was.Slipped the secondary on the shaft like any other time.Installed the belt and proceded to start the sled.Since carbs where dry and tank was empty all summer,after putting gas in her..it sure took alot of friggin pulls to get her fired up.Thought I was going to have a heart attack a few times.Changed the plugs and added fuel in the plug holes.Took a while,but probably I flooded it to.Proceded to drive it from my shed to the garage.Gave it a wash with the water hose first,then parked it inside the garage.
Now I decide to remove the air box and get the carbs off.Of course one the damn screws on the boot to the carb got f@$ked up.Had to drill the head of the screw to release the carb on one boot.Fine,I'll look for new screws later.
Then I removed the secondary like nothing,as any other time.Took my alignment tool and slipped it over the shaft and began pushing it right to the back.It seemed very snug and didn't feel right.Anyways pushed it in by hand to the end.Tried to lower it on to the primary,pulling back a bit...but it would not move.All of a sudden it was very tight on the shaft.I had to use 2 hands to swing it down,but couldn't move it forward to bypass the frame .This really ticked me off.As I tried to lift it up,it was actually moving the jackshaft.But could not get it off the shaft now.I was really starting to blow.Got a short fuse and the words were just a flying.I finally flipped out trying to find my small puller in the garage ,but found it eventually.Put a small bolt in the hole of the shaft and proceded to pull out that damn tool with the puller.It was friggin tight as hell.What gives here.Now I took my secondary and slipped it back on and it was tight also.Now my thoughts were.. What the f**k???? Took a scotch brite pad and polished the shaft up and tried again.Same friggin thing.Went in the house to cool down for a few minutes.Then back to it again.I tried different positions with the secondary,one position it slipped on ok.Tried rotating to a different position ,sliding it on was really tight again.There is no way my alignment tool will even slide all the way on.So am I to assume that the damn shaft is bent slightly on the end or WHAT???Can't think what else.Alinment tool slides on my SRX jackshaft like nothing.You can imagine I am real pissed about now over a simple task.To you experts out there,what do you think has happened.I guess if it is bent just enough that the tool won't slide straight on and the secondary also.I did blow a belt last year,but how would this do anything to a shaft?What you's think?Lost here,thinking the unthinkable.#$%&* #$%&* #$%&*
 
just lookig for now

I am checking on prices for a new jackshaft just incase.Is anyone parting out from a 2001 SXR600,maybe you have a jackshaft that is good.
 
Didn't I tell you that your clutch alignment was probably off!!! And you blamed the Ultimax belt. Shame on you!!!

Keep us posted on what ou find. It's hard to believe that the jack shaft would be bent in that short distance from the bearing to the end????? Any burs on the splines???

BTW, I'm the proud owner of a Viper (not sure for how long though).

Cherrs

Exciterfan
 
??????????????????????????????Ha!!!!!!Did you say the "C" word.

Yes it is hard to believe it would be bent from the bearing to the short end.That is what I can't understand.What year is that Viper,because a friend of mine is looking for a Yamaha,and if you are thinking of selling it,let me know soon and how much for it,miles,etc...................................Doug.I told him about the Yamaha TY Ride in Feb.which I will being to and she thinks that is cool..but he needs a Yamaha.I told him I would look for one for him.
 
well it's a no go again.The secondary is sliding on and off ok,but the align. tool will not.Actually I pushed it on gently this evening and now it is stuck in place.Have a little over an inch to go,but won't.Can't get it off this time.Destroyed my small puller arms,just can't get it off.Used the hammer on the tool to back it off,no go.Slowly destroying the align. tool.Can I say the words that were flying out of my mouth.Had to leave it and come on here because I probably would get a heart attack in there if I lost my temper and would of destroyed the friggin sled to with my hammer.I guess the shaft is thicker past the splines then on the SRX.Yet I can switch secondaries from one sled to the next.GO FIGURE!!!.This SXR ain't getting a clutch alignment I guess and I'll have to cut the align. tool to get it off.What a waste of money.Might as well park this sled and look for another used one.I thought the YAMAHA ALIGNMENT TOOL fits from one sled to the next.They are only one year apart.This really blows me away.I do things by the book and this is what I get...$hit.Maybe it is time to give up this hobby and find something less stressfull.Don't need to deal with things like this at all.#$%&* #$%&* #$%&*
 
Got that SUCKER!!!!!! off finally.Yep,there is no way that Sled Pro Tool will slide over the jackshaft all the way.It is where the shaft thickness is greater after the splines.Secondary slides over shaft perfectly.WEIRD!!!!Again Sled Pro Tool slides over the SRX jackshaft end with no problem.Secondaries can be switched between the 2 sleds' jackshafts.Yet the Tool will not slide on the SXR jackshaft.I AM STUMPED!!!!!!!Can't align my clutches now.AHHHHH!!!!!
PS:did throw my hammer at the garage wall when things got heated up.I destroy things when I get mad,can't help it.It's me.My old man was the same way,but his temper was scary.Mind you I am probably and surely going to get more scary as I get older.My wife runs for cover when I get that way.#$%&* She says I am like my old man and probably will have a heart attack at a younger age.STRESS MAN>>>STRESS.My probem is when things don't go right,like I mean things that should just fall into place..but don't..that is what sets me off.
 
This is even more weird.The parts numbers for the jackshafts and the secondary sliding sheave for the SRX and SXR are identical.If both sheaves will slide on the shaft and even when you switch from sled to sled,why the hell isn't the Sled Pro Align. Tool not .Will take secndary off the SRX next and try again with the tool on the jackshaft.Used it on the SRX about a couple of weeks back to align the clutches.No problem at all then.I simply cannot understand this.
 
Friend of mine stuck the belt in the secondary without realizing it, gave the sled a little too much throttle and when the heel clickers kicked in it was enough to bend his jackshaft. Put the secondary and belt back on. Start the machine and rev it up to so the clutches to engage (back end jack up obviously). Now watch the head of the bolt that holds the secondary on and check it for a wobble. Bet ya it goes up and down about a 1/4 inch.
 
I was thinking of that YamerDown,but have the carbs off so I can align the clutches,because the rear motor mount bolts are now showing in order for me to move the engine accordingly.Don't have HC's on the SXR .I am stuck between a rock and a hard place here.If I can't get the Align. Tool on the shaft,then I can't align properly.But it WON'T SLIDE ON.AHHHHH DAMN.
Got some thinking to do here for sure..with hammer in hand...LOL
 
HCs or not, if the belt is stuck and you nail it the shaft will bend. I know it's a pain to put the rack back on but you are quickly going to rule out a bent shaft. I'd rather put the carbs back on to figure it out then destroy my alignment tool. You should't need to completely remove the carbs for alignment anyway. Just loosen the boots and flip it up out of the way (leave all lines attached).Just a thought.

You could also open the chain case, remove the chain and spin the shaft by hand, but that's more work then putting the carbs back on. lol

Good Luck!!!!
 
I got your point.Was going to clean carbs anyways.Will be draining chaincase oil and checking the parts inside to.Turning shaft by hand,I think not.Can I spin it 4000 rpm by hand....no...lol.
 
You can do it! lol

Why not loose the chain, put the gear and retaining bolt back on and spin it with a cordless drill or impact gun?
 
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Doug,

Settle down boy!!! We don't need you blowing a gasket.

Do as everyone is suggesting and pull the chain case gears out and spin it by hand . You don't need 4000 RPM to see if it's bent. Once you have the gears off, you could put the secondar back on and see if it has a wobble when you spin it. You could also take it right out and check it with a stright edge.

I was going to suggest you clean up the Jackshaft with some fine sand paper, but it does sound like you've bent it based on the difficulty getting the tool off. Just so you know, my Sled Pro tool slides on my SXR jack shaft easily.

Try giving Tony Pinter a call 204-955-9109 or 204-2242793 he'll have a jackshaft for you at a resonable price (cash).

Len
 
I don't think the shaft is bent at all at the end.If I take the secondaries both from the SRX and the SXR...they both slide on without a problem.If the shaft was bent,they would also bind themselves.I cleaned out the Pro Sled Tool on the inside,basically it is the same diameter as the shaft...25mm.Now the tool slides on with no problem at all,and I can see that my primary center to center is off and the offset is off a little to.I remember when I put my Reed spacers on the SXR,I shimmed the back of the motor so the airbox wound not rub the steering shaft.Will work on getting the clutches aligned this weekend.
I inspected the w-arm on the SXR and it is in great shape.With 10,000km's on the sled..there are no cracks or breaks anywhere on the arm.Going to take the front shock off to replace the shock bushings with needle bearings bushing,so there will be no more play in them ends.All the aftermarket wheels that I installed last summer,ie)polaris sized idlers and the 7.5" rear wheels are all in great condition.Nothing is worn on them and the rubber is in tack.The hyfax is like new yet also.This is the same wheels I put on the SRX,should be good to go.The ice-scratchers that I installed on the SXR work real good in low snow or ice to hard packed conditions and it shows on the hyfax.I love that little 600 Ditch banger and I really ride it hard and do a lot of jumps with it and nothing is breaking at all.Have the center shock at minimal preset and the limiters are a little less then stock setting.I don't get that much pressure on the w-arm then.Will drill and install grease fittings where the arm connects to the mounting bracket,and will also do the same to the transfer rods where they mount to the rails.Will make sure the bushings are snug in the arm also.This is one tough 600.Like I said,I ride it hard al the time.I look for things to jump.I remember being air borne a couple of times last season. 20 to 30 feet airborne and landing pretty hard,but the sled keeps on ticking.Bullet proof all around.Compression is still 120 across the board.The Ripsaw 1.25
track is really awesome on it to.Can crawl out off anything..just pin it and she digs out.
 
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The jack shaft just needeed a little clean up!!!

Don't be afraid to try an Ultimax belt once you get your alignment done. I've had no problem at all with them. They grab really well.

I have my 2003 MXZ 600HO for sale right now to see if I can keep the Viper.

The MXZ is a really good sled, with reasonable miles on it. It is in MINT condition. If you know any one interested please let me know.

Cheers
 
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