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clutching for an 09 XP

You guys keep referring to a spring end cap... what is that?

Do you maybe have a part number that I could look at for the online parts catalog?

Thanks
Shawn
 
turboal said:
no , actually we kept the gearing once we got the end loadcorrect . you could gear down , just need a bit more tip weight to get the up shift back .
we used the 2mm over size rollers to achieve this '.
we combined this with the shaving of the power valves 200ths . this puts the export opening when the guilletines are closed back close to were it was on the 06 model 800.
they use the opening of the power valves at 7400 as a wa to beat the sound emmissions test on the tail . you can pass by at 45 mph and not be intothe power valves as when they open they exceede 100 decibels .

the larger opening allows the pipe to come to pressure sooner and gives you the mid range pull you are used to on the older 800 motor it oopened at 5800rpm and in its closed position it was a 30 mm opening and the r motor is 25mm.
Click to expand...

Al, I PM'ed you as I might know how to get around this late opening of the exhaust valves. Let me know if my idea is valid and if so I could build a prototype for you to try.:beer;
 
Dynamo^Joe said:
Part # 417222759
(Spring Cover assembly)
Click to expand...

Thank you Joey!! :beer;:beer;

So from looking at that diagram I am still a little confused... are we saying the bushing wears down quick or the the whole spring cover wears down? Ski-doo has the same part number since 05' is there a way to check if your spring cover is out of spec?

Cheers
Shawn
 
This is from my summit setup sheets.

If have an 800R – THEN, NOTE BUSHING WEAR – The TRA7 is Notorious for premature bushing wear due to inferior materials and narrow bushing width. Visually inspect the coating of the 2 bushings for wear. Using a bore gauge, measure the inner diameter of the bushings –

Measure point must be 5mm (1.4”) from the bushing edge.
*Spring Cover bushing – Replace bushing or cover if the inner diameter is a 30.40mm(1.197 in)
*Sliding sheave bushing – Replace bushing if inner diameter is 40.30mm (1.587”)
Click to expand...
 
I don't know why, but the bushing kept coming out of mine. :confused:
I put DJ's clutch kit in mine and on the second ride with it one of the cotter pins holding the weights in the end of the arm came out. the weight pin tried coming out and was hitting the inside of the clutch when it tried to spin out against the ramps. This put a side load on the arms and broke one of the arms. Then the left over piece of the arm flung out and was stuck on the tip of the ramp and wouldn't let the clutch disengage.
I took it in to the dealer like this. They pulled it apart and would not cover it under warranty because I put a aftermarkt clutch kit in. so they charged me $90 labor for pulling it apart and wanted $1,300 just in parts for a new primary. They were also nice enough to some how brake off the primary bolt in the inside sheave that goes on the end of the crank. Sorry, but I don't have and will not spend $1,300 plus labor to repair my clutch. I took the clutch to a machine shop and he drilled out the broken bolt and taped with different threads.
I orderd two new arms, roller bushings, weights, and the bushing that goes in the end of the spring cup. I orderd oem doo cotter pins to hold the weights in the arms. The cotter pins that came with the dalton wights were made of alot thiner gauge wire then the doo ones. The dealer removed the bushing out of the end of the spring cap because it was trashed. I took the complete clutch to my crank guys shop to see if he could balance it. We were trying to find stuff to get it put on his balancer and he asked why I wanted it balanced. I showed him where the weight had took some aluminium material out of the inside of the clutch. He laughed and said at most that is a gram of material and wasn't worth balancing because of that. He said if I wanted it perfect just drill a 3/16' hole through it 180 degrees off of the missing material so I did.
I put a new bushing back in the spring end cap with red loctite. That only lasted a few miles. I looked up what doo uses. It is some kind of green sleeve locker from loctite. I put it in with that one night and rode the next day. came out right away again. Then I bought the cleaner/primer loctite recomends to use with the green sleeve locktite. cleaned the spring cup and outside of bushing with the cleaner/primer put lots of locktite on it and let it sit for 3 days before riding. Lasted about 9 miles this time, but still came out. Done for last year. So I am going to order a new spring cup from doo and pray that it lasts. :mad:
I have no idea why the bushing keeps coming out of the end of the spring cap because their is no real force pushing it out of the spring cap. It just slides on the sheave shaft.
 
Dynamo^Joe said:
This is from my summit setup sheets.
Click to expand...

Hey Joe, I understand the bushing wear thing but does the spring cover assembly actually wear? Thanks.
Oh yeah, could you also list the part number for those bushings your talking about. Thanks a ton!
Hope it's snowing where you ride!
 
Last edited:
Nice!!! guess I will have to put in the same as what I had and have it wear out after 800 km again. Getting frustrated with all the xp issues, beginning to think I have a mod sled judging by the amount I have to F@#$ with the clutches.
 
turboal on the 08 xp 800 what primary and secondary springs did you end up using.Your write up was great.Thanks rad.On the 163

turboal said:
relax , relax relax .. wait till you have it in the snow and have 3 tanks thru it before you go and throw a pill of cash around .

contrary to most thoughts on last years clutching on the 08 ..doo only missed with one componnent in the transmission .

one underlaying issue the 08 had was a very short life on the spring tower capbushing clearance. 07/08 the materials wer soft and achieved a to broad a clearence very shortly and would effect transmission oporation emmensely .

if the tower cap is good the item i talk about is the end load on the secondery spring .it was to soft for the type of track doo selected . duro was hard and lugs didnt bend much , this translates to a much higher load and a strain in the secondery as it up shifts and looses the amount of belt traction patch.

we tested all season on the doo transmission and we as well put the team secondery on to verify that we werer on the correct track , we saw the exact same symptoms and it took the exact same direction to correct it ,

when we did we saw the track speeds increase to were we thought the new chasi would send it .

no gearing change needed .
163 track speeds went from a typical deep snow scenario here of 37 mph to 54.
the 154 saw the same jump in track speed and the belts were at a temp and wear factor that was now acceptable .

the 09 approach does make me scratch my head but i want to seee what it actually does first before the speculatiion goes wild .

for 09 ski doo has changed the spring tower cap material and assure me they have it fixed . we hope so and will be the component that we watch closely out of the gate .


remmember relax relax relax till the sled proves to us we need to change it .

doo spends a lot of effort in trying to deliver a middle of the road set up that as it goes out the dealer s responsability for the fine tunning his customers need for there riding area is left on there shoulders .

all things said we put a yellow epi sec spring in last years sec , it was a 50 lb increase over what doo sent out and this one item made the sled absouloutly rock . no other changes needed .

on a note we achieved the highest track speed in deep snow going vertical on the gps with this set up in our big bore on this motor .

over all you should achieve a 7 mile an hour gain over the older rev chassi if you get the clutching correct and as well if it doesnt have a worn spring tower cap .

this bushing carries an immence load and when it wears pre maturely it is no wonder a lot of chasing was done 07/08 to find a good set up .
Click to expand...
 
turboal on the 08 xp 800 what primary and secondary springs did you end up using.Your write up was great.Thanks rad.On the 163
 
If not--what numbers on here are wearing out in the spring tower assembly (tower cap)?

IMG_2762.JPG
 
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