I'm trying to figure out how to align my clutches on my '02 700. I used the offset bar that goes over the primary and rests on the secondary but my primary clutch still gets hot. Someone told me that bar doesn't tell you if your clutches are parallel it just does offset. I'm getting frustrated with this thing and i don't want to start burning belts.

lay something flat across the back side of the primary clutch to extend over to the edge of the secondary clutch sheave.there should be 5/8 ths of an inch between the back of the secondary sheave and the flat piece.[straight edge of some sort].1 inch with electric start gear.

check clearance between the PTO side hardstop and the engine. there should be a .010 gap. use a feeler gauge and make it right. this is info directly from my mechanic.

Well Sounds to me like the 2ndary clutch is too far in towards the bearing and the bar is laying on top of the rear sheave..

will the clutch float?? or slide on the shaft any?? towards the belly pan can you get the bar to sit on the back side of the rear sheave?

It kinda sounds like there is no float and and too close to the bearing housing

the 2ndary needs to be shimmed out some so the bar slides down the back side of the 2ndary clutch

I started aligning my 2ndary clutch so there is some both positive and negative float with the 2ndary being as close to perfect alignment in the middle that..

The clutch has some side to side float to it. When I had the bar on it the bar was behind the clutch touching at the back, .060" gap at the front like spec says.

Are you burning belts?? Clutches sound like the are aligned.. if with in spec..


could be a few issues

chaincase chain tightener is too tight, should be finger tight against the chain
it should be used as a guide with lite force against the roller, too much force will cause binding
and cause the belts to smoke.

or

2ndary clutch not working correctly, pull it apart check clutch buttons and helix and spring, could be the spring just does not have what it needs or it has reached it's shelf life expectancy replace spring or use a different spring depending on what you are riding..

well I haven't burnt a belt yet, and I just changed my secondary spring tonight so I will try it out tomorrow. The buttons looked alright, and my chain is setup just as you said finger tight.