ZR 800 Secondary clutch problems - HCS Snowmobile Forums

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Old 02-08-2008, 11:39 AM   #1 (permalink)
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Current Sled(s): 2014 XF limited 8000- '97 trail-'94 Indy Lite
Previous Sled(s): 2002 Polaris XCSP EDGE 600
Location: South Central MB
Favorite Riding Area: Whiteshell MB - Spruce Woods
13-14 Mileage: 1900
12-13 Mileage: 2100
11-12 Mileage: 5
10-11 Mileage: 1500
Age: 30
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I have a 2001 ZR 800 and i am having trouble with the secondary clutch opening prematurely.

I notice it at slower speeds in heavier snow, it seems like the secondary opens up all the way bogging down the motor and chewing through belts.

also last night when we were riding i would crack the throttle at about 70 mph and the sled wouldnt really speed up and rpms seemed to stay constant. seem to be some vibrations and noise coming from the secondary as well

I have put all new bushings in and replaced the spring

any suggestions?
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Old 02-08-2008, 12:35 PM   #2 (permalink)
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Current Sled(s): 2013 F1100 Turbo Sno-Pro Limited
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Location: Algonac,MI
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sound like you didnt wind the spring properly. take off belt and try pushing clutch open by hand. if it is pretty easy the spring is not wound properly. Lump
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Old 02-08-2008, 04:28 PM   #3 (permalink)
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Join Date: Oct 2005
Posts: 165
Current Sled(s): 2014 XF limited 8000- '97 trail-'94 Indy Lite
Previous Sled(s): 2002 Polaris XCSP EDGE 600
Location: South Central MB
Favorite Riding Area: Whiteshell MB - Spruce Woods
13-14 Mileage: 1900
12-13 Mileage: 2100
11-12 Mileage: 5
10-11 Mileage: 1500
Age: 30
Riding Since: 1996
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How do i go about winding the spring properly? if i remeber right i did wind it up to put some tension on the spring.

If i remember right you need to wind it clockwise...?
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Old 02-08-2008, 10:20 PM   #4 (permalink)
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'01s were the only 800s to use that light yellow spring. swap that out for a red-white 02-'04 zr 800-900 spring. just make sure th esping is seated in both holes, yes you need to turn the cover clockwise-preloading the spring- to get it on the studs. its very hard to do that wrong, one way will be the wrong way..loose... and if you attempt to go to far it beginns to require a Lot of force.
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Old 02-08-2008, 10:42 PM   #5 (permalink)
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Spring could be worn out as well, they do lose tension over time.
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