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Discussion Starter · #1 ·
Decided to fine tune the clutch offset and belt deflection on my F1000. Purchased the 1.507" offset bar from Cat (#0644-496) and the necessary deflection shims/washers for the driven clutch. The driven was approximately 1/6" further out than the 1.507" bar (which is technically still within spec BTW) so I removed one of the offset washers from behind the driven clutch to move it inwards slightly, making the offset bar now set "perfectly."

With 150 miles or so on the belt, I needed to tighten up the belt deflection a tad. The driven came with 3 thick, 2 medium, and 1 thin deflection washer. I simply removed the 1 thin washer and replaced it with another medium washer, and this set my belt deflection about perfect – nice and snug now, and I couldn't move the belt by hand around the driven clutch anymore.

However, with this carefully "fine tuned" setup, we found out (after more than a little head scratching) that the backside of the driven clutch helix was binding BADLY directly against the cover/faceplate of the Diamond Drive gearbox. I mean TIGHT... could NOT move the the driven or the track at all, even with two hands. In fact, we figured the brake had somehow locked up for sure. After re-installing the offset washer I'd removed earlier (but still leaving the deflection the was I just adjusted it) all was well again.

You probably don't have to worry about much if your just adjusting belt deflection one way or another, but if you mess with the offset of the driven clutch, especially moving it inwards at all, make DAMN sure the backside of the helix is not biding on the DD cover/faceplate. This could obviously cause a LOT of $$$$$$ damage. – Roy
 

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All dealers should be aware of this, it was on the 07 tech update, You must have at least 2 thick offset washers or the secondary will hit the gearcase
 

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All dealers should be aware of this, it was on the 07 tech update, You must have at least 2 thick offset washers or the secondary will hit the gearcase[/b]
Well that solves my problem, I have the alignment bar and found that my secondary was also out about a 1/6 or so. Was considering going to 1 .060 shim and one .030, but I guess this stomps that idea. Any other tech updates we should know about and/or is there a place on the net that I can view them???
 

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Discussion Starter · #6 ·
wow,, i just did the clutch kit from dd and did not notice any miss alignment??? did it scratch your cover???[/b]
Sure did. Nice circle mark on the cover from the back of the helix. Didn't actually RUN the sled of course, as we found it was binding right away thank God! LOL... learn as you go I guess, but I've been doing it the HARD way so far this year! – Roy
 

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dammm,,, well at least you were smart and found the problem ,, most might of missed it and kept on trucking.....and when i was at the my dealer // shop ,, they were talking about a bad wireing harnest,, so go over yours as well,, mine is fine,, just thought you may need to know??
 

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Discussion Starter · #8 ·
Thanks Krom – you're absolutely right... as usual! Checked the two washers that came on my sled, and indeed, they're the thicker .060" washers. Figures, after I bought the new tool and a bunch of washers to get it "just right..." gotta' leave it just the way it came... LOL! – Roy
 

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This is old, but I am am searching for some info.

My sled has 4 60thou shims/washers behind secondary. From what I have read, you must run at least 2 ????
What are others running for shims ?
F&F
 

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Does anyone thing cat actually checks offset at the end of the assembly line ? and adds shims to correct ? or just make'em all the same ?

Wonder why some came with 2/3 and mine with 4
 

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Does anyone thing cat actually checks offset at the end of the assembly line ? and adds shims to correct ? or just make'em all the same ?

Wonder why some came with 2/3 and mine with 4[/b]
maybe 2 stuck together when they were throwing it together? have you ever seen how fast assembly line workers throw parts on? :head_hurts:
 

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Flash I have only seen 5 or 6 sleds with the clutches off but they each had just the two thick shimms like mine does.[/b]
The ones that were off, did you need to add or take away ?
Hard to assume take away since they need to have 2 but with AC assumption is the mother of all fuck ups
 

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I only put the bar on mine and my bud's other sled..... they both should go in to be "on" but they can not as mine has contact marks already. I'm considering tooling a bit off the clutch to allow shim removal.
 

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There is no way to know how many shims should be there without using the alignment bar to check. Just to confuse things further cat changed the secondary for 08,
On 2008 machines the clutch wont hit the gearcase, even with no shims.
 
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