Secondary Clutch Spacing?

[MikeMetzger]

In the midst of my overhaul I pulled the secondary clutch off and I believe I left the spacers on the shaft. However I stumbled upon two very small spacers that Im not even sure if they're for the clutch or not. My question is, Is there a certain spacing/spacers that come stock? Or are they all different?

 

[crashnbash]

You need an alignment bar to know what size shims to put behind the secondary.
A picture of the washers you have left over would help to know where they go. If they are much smaller than the ones behind the secondary they are probably used to set the secondary float.

 

[MikeMetzger]

Yeah, there was one large back spacer, then I found 2 very thin spacers. I have a dealer I was planning on taking it to my local dealer to use that alignment tool, but thought it was at least worth asking. Thanks!

 

[AK IQ Pilot]

As mentioned, a picture of the washers/spacers you found would be helpful.

You can set the back spacing and float without an alignment bar. This is especially helpful if you have lost or mixed up the spacer and washer shims from your secondary clutch and jack shaft. Also helpful if you are installing a different secondary on your sled.

The idea is to position the two "fixed" sheaves into their correct position. When I say "fixed" I mean these two sheaves don't move (in relation to each other) as the clutches shift ratios.

Essentially the outer edge of the secondary clutch should be spaced 2.50" from the inner web of the primary clutch. This is for a primary without an electric start ring gear.

Take two straight edges, one behind the primary and the other on the flat face on the outside of the secondary. Pull the secondary out against the stop washer. Measure the distance between these two faces. It should be 2.50". IF it's less than 2.50" then you need to add washers under the bolt holding the secondary to the jack shaft. If you have more than 2.50" then you need to take away a washer.

Once you have that distance set then you need to adjust the float of the secondary. You should have about .030" of in and out float when pushing the secondary in and out on the jack shaft. If you have more than .030" then you add spacers to the back side of the secondary. If you have less than .030" then you need to remove spacers.

From the OP it sounds like you may have found spacers hims from behind the clutch. If you found .050" worth of shims and you have .080" float then it's pretty obvious where these shims go.

 

[damx]

I don't agree, .030" is not enough float, we all set about .060-.080 " of float.

 

[AK IQ Pilot]

I don't agree, .030" is not enough float, we all set about .060-.080 " of float.

Additional float isn't going to hurt anything. Spec is .030" but I agree with you a little more won't hurt.

 

[MikeMetzger]

Wow thank you very much! Thats very very helpful. I would put some pics up of the washers, but the sled is at my brother in laws since he has a garage Ill have to go back over there and get pics of the washers for ya.

Thanks again! you guys rock

 

[MikeMetzger]

Question, what is "float" another word for tolerance?

 

[rmscustom]

Float is the amount the secondary is allowed to move back and forth.

 

[AK IQ Pilot]

Question, what is "float" another word for tolerance?

Float is the In and Out movement in the secondary, The secondary clutch on a modern Polaris sled is designed to move in and out on the jack shaft. It essentially floats on the splines of the jack shaft.

 

[MikeMetzger]

Okay, so float is the amount of "play?" Because when I put it back on and tightened the bolt down, it had play in it which is what led me to believe I had definitely screwed something up in the placement of the spacers.

 

[BigTree]

Correct. The secondary should move in and out when the bolt is tight.

 

[MikeMetzger]

Whoa, crazy. I completely get how the clutch systems "work" but I also know they are constantly changing/bettering the system in ways. I swore that I just took the secondary off and left all spacers behind it on as there was no reason to take them off and possibly screw it up. But when I went to tighten it back down I just didnt think it was right for it to just be banging around like that lol. I still plan on making sure they are aligned properly for the season, but this is good info to know. Thanks guys!

 

[cascadesnowjunky]

You have to be carefull when you pull the secondary, the grease will make some of the spacers behind the clutch stick to it. Then if you do not see them they will fall off the clutch and will most likely get lost.

 

[MikeMetzger]

Thanks! I think that might actually be what had happened with these two smaller washers. I'll check it all out tomorrow and see what I find.

 

[waxer]

I have always adjusted float with the washers behind the bolt & offset with the shims on the shaft behind the secondary, can it be done either way? Honest question.

As mentioned, a picture of the washers/spacers you found would be helpful.

You can set the back spacing and float without an alignment bar. This is especially helpful if you have lost or mixed up the spacer and washer shims from your secondary clutch and jack shaft. Also helpful if you are installing a different secondary on your sled.

The idea is to position the two "fixed" sheaves into their correct position. When I say "fixed" I mean these two sheaves don't move (in relation to each other) as the clutches shift ratios.

Essentially the outer edge of the secondary clutch should be spaced 2.50" from the inner web of the primary clutch. This is for a primary without an electric start ring gear.

Take two straight edges, one behind the primary and the other on the flat face on the outside of the secondary. Pull the secondary out against the stop washer. Measure the distance between these two faces. It should be 2.50". IF it's less than 2.50" then you need to add washers under the bolt holding the secondary to the jack shaft. If you have more than 2.50" then you need to take away a washer.

Once you have that distance set then you need to adjust the float of the secondary. You should have about .030" of in and out float when pushing the secondary in and out on the jack shaft. If you have more than .030" then you add spacers to the back side of the secondary. If you have less than .030" then you need to remove spacers.

From the OP it sounds like you may have found spacers hims from behind the clutch. If you found .050" worth of shims and you have .080" float then it's pretty obvious where these shims go.

 

[go-on-two]

AK, Where did you get the 2.50" measurement from, is that out of the service manual?? Same number for 2013 models?? I think the manual also said .060 +or- of float..

 

[AK IQ Pilot]

AK, Where did you get the 2.50" measurement from, is that out of the service manual?? Same number for 2013 models?? I think the manual also said .060 +or- of float..

The 2.50" number is the basic measurement that all Polaris sleds with a P85 Primary and a Team Secondary have. It doesn't come from the manual. It just comes from throwing motors in sleds for a lot of years. You should still put an alignment bar on the clutches to get them perfect but the 2.50 number will get you close. It's especially helpful if you take the secondary off and lose the shims behind it and need to get it back in place.

Manual may say .060" for the Pro, I will look tomorrow. I only had an IQr manual yesterday, it says .030" of float. This is my first Pro ever. With so many years of race chassis info clogging my brain I may have to read up on the Pro a little more.

 

[AK IQ Pilot]

I have always adjusted float with the washers behind the bolt & offset with the shims on the shaft behind the secondary, can it be done either way? Honest question.

Sure it can be done either way depending on which way the clutch needs to go to get the correct offset.

I guess in the OP Mike was saying "Hey, I got some extra washers and shims, they may go to my secondary clutch, what should I do?" The reality is if you only have one sled and you found a couple extra shims with a 1.125" ID then you pretty much know exactly where they go. The challenge starts when you find some extra washers with a 5/16" ID. They might be from behind the clutch bolt and they might be from the lawn mower. It's hard to know for sure exactly where they go. Thats why I suggested using the 2.50" number as a starting point.

I'm starting to second guess myself here though. I've used the 2.50" number on ProX, Edge and IQ chassis sleds for the last decade. I've never actually measured my Pro. It might be different.

 

[waxer]

This was posted by Mountainhorse in another thread, hope it is ok to repost?