freshening up clutches

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stealther27

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Sep 15, 2009
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Jefferson, WI
Alright so I'm starting to get my sled ready for winter and with just over 8000 miles on my srx I'm going through my clutches. I'm starting on my secondary and as I'm taking it apart I was wondering how can u tell if you need to replace your secondary spring? Also on the inside there's three plastic ramps, can these be replaced? I was looking through the microfiche but couldn't find any of these pieces. Just trying to figure out what I all need to replace? Thanks
 
If you mean the plastic ramps then yes you can replace them.you can pop them out with a flat head screwdriver. If they look like they have groves in them I would replace them. Mine looked like they had metal showing. Not sure if it was metal but necer the less they were groved. If you look on yamaha's web page there is a section for parts. I have been using partzilla. You can look up your sled and find just about any part you need. Hope this helps.
 
yep that's exactly what I was wondering, I also couldn't remember that name of the other website that's what I was looking for. gonna go check that out. thanx man
 
Also I talked to Hauck and they said to replace your springs every 2500 miles and should take them out when storing the sleds over the summer. This will take the tension off them and last longer.
 
awesome thanks Norwegian that's what I had been looking for. I could on the microfiche on port yamahas website an they didn't have the diagram for the secondary available. Also has anybody instead of ordering individually parts for there primary just ordered the tune up kit? not sure what is all included or if itsa better deal?
 
ok gotcha. well the repair kit which im guessing is the whole thing at hslm for $800 ouch! But the tune up kit is like 180but like Norwegian said after doing some more researching you have to buy all the other tuning parts separate. man maintenance items on these sleds are not cheap. Also I popped those ramp shoes off my secondary all 3 were worn down but when they came off theres still some material left in the hole where they mount any ideas how to get all of it out?
 
punch them through from the backside.

while your in that secondary, consider replacing the 3 bolts used for setting belt tension. they are a wear part and when worn they can upset the adjustments. also look at the wear plate they ride on. most likely you will see where they have augered into this plate. cheap fix is to smooth the roughness out and flip the plate over. next best is replace it. dont forget the loctite.

for the primary, order what you need to refresh it, skip the kit. pull the clutch, disassemble, and assess the worn parts, replace as needed. theres some parts in the kits that will lay around on a shelf for years. no money to be saved there, in my opinion.
 
alright thanks for the info snowdad 4 I don't have too much experience on working on clutches besides a little tweaking, so just trying to learn the ins and outs of it all. Don't know any other website that has this much valuable information.
 
Clutches are never cheap, though they are the pretty much the most critical parts of your sled.
 
Oh I definitely agree I would much rather spend a little extra now an know that I won't have any worries this season on the trail wondering if something in the clutches is gonna take a shot.
 
Snowdad 4 well I was thinking about ordering all the parts I need for my secondary and in your post u said considering ordering the wearplate and the 3 bolts for it used to adjust the belt, where is this on the microfiche? There's 2 different plates just want to make sure I order all the parts at once.
 
i would assume you would find it for your model under "secondary sheave", but heres what i have for part numbers:

plate=8BV-17656-00-00
bolts=90105-06734-00, you need three
plastic buttons(ramps)=8AV-17688-10-00

on the three bolts, you should have some flat washers used for setting deflection. check your bolts and see if you have any now. they come in .5mm and 1mm thicknesses. you may consider ordering some if you dont have any. sorry, dont have the part numbers on hand.

the three screws securing the plate are rather soft and can be difficult to remove. be careful not to strip the heads. heating them will loosen the bond and make removal easier. as mentioned, you can smooth over any gouges and flip the plate over if you want to save some money.
 
thanks for the part numbers that really helped me out. I was looking at the plate an tried to remove it but just like u said I will have to heat up the bolts first. Also I looked at the bolts an saw that there are no washers there at all?
Also Im not sure if the 2 bushings need to be replaced but Im thinking that with over 8000 miles I might as well get new ones?
 
ok that's what I was kinda thinking just wanted to hear it from other people. So gonna order that stuff up tonight an get going, thanks for info guys.
 
at the very least, replace the movable sheave bushing. part #90384-38243-00.

the other bushing is for the helix. take your helix and turn it upside down on the secondary shaft and see how smooth it slides and how much wiggle/wobble it has side to side before popping for a new one. granted your high mileage but most people like to play with the helix angles and i would question if it was original to the machine. who knows. post up the number on the helix and i can reference it.

as for the washers, if i was doing what you were doing i would order 3 each of 90201-061H1-00 and 90201-06431-00. your only out around $6 and they will be tagging along with your shipping charges. you may find you need them after all the refreshment of the clutch. most people pull them out and discard in an ill attempt to stop a squeaking belt. too bad.

again, check that helix before opting for a new bushing, i would. i am a cheap guy and dont like to buy things i dont need.
 
I went ahead earlier and ordered just the 1 bushing so far. I am running the loaded 8dn-20 setup the helix is 54/44 I got it from a buddy who had it for a spare that didn't have much use on it when I got it. I ordered off of partzilla and got 3 of the .5mm washers, they apparently don't carry the 1mm washers anymore.
 
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