3500 kms and the primary clutch was getting a little noisy. Still worked fine but the knocking when my quad was idling was bugging me. Bought a puller bolt from EPI, made all the necessary holders and wrenches to get the spider off and got to work. Pulled the clutch apart and found the bushing in the outer cover was out of spec. Measured the bushing in the movable sheave and it was good but I decided that while it was apart, I might as well do that one too. Got my machinist buddy to turn some new bushings out of oillite bronze and pressed them in. Put the whole thing back together and man did she slide pretty!! Checked the wear shoe clearance and found that they were a little big so I made some brass shims out of .006" thick shimstock and put them under the wear shoes to decrease the clearance. It took a bit of dicking around to get the side shoe clearance the same on all shoes but I got it pretty close. Put the primary clutch back together and reinstalled it on the bike. Fired it up and it was so quiet!!! All I could hear was the motor! It is definitely worth a guys time to tweak the primary out if little knocks bug the crap outta you. I checked the sheaves while I had it apart and they were amazingly in good shape so I didn't face them off. The worst part was trying to get the spider off the main shaft. That sucker was really on there!!! Can't wait to take it out this weekend and give it a real workout!!

 

I had the same idea & you did.. My 360 needed a primary rebuild, but the damn stealer ended up breaking it after trying to remove the spider from the sheeve, so I ended up buying a brand new primary @ there price so I thought I came out alright. But while I was looking at the wear shoes I thought why would I pay $10 a piece for these little damn things when I can just shim them, I'm glad it worked out for ya because the next time that's exactly what I"m going to do..

 

It is nice to get it done.My shoes were ok but I have put about 200 miles on since doing the outer bushing and inner and it is staring to make juuuuust a little noise again.I used the oem bushings though.
02 650 camo

 

Shimming the wear shoes was a pain but the results were worth it. Oillite will work good for the outer bushing but I'm not too sure about the inner bushing as oillite has-----well-----oil in it!! Have to wait and see how it works in the long run. If the inner bushing leaches too much oil, I'll have to replace it with a stock bushing.

 

I just redid mine with bronze bushings, seems to be working real good so far, used bronze for the secondary bushings too.

 

589650, the only reason I used oillite was to give it a little lubrication but regular bronze was my next option. I don't know why they don't show an OEM replacement bushing for the outer cover as the factory one is just pressed in like the one in the movable sheave is. Doesn't make sense to me.

Uinthas, I kinda got the idea to shim the shoes after watching the machinist at work shim a piece he had in a 3-jaw chuck in the lathe. Then I read on Kawieriders that one of the guys there had done it so I thought what the hell, might as well give it a go. I cut the little discs out with the wife's scissors (don't tell her!!!). I was surprised how easy it was to cut as I thought I would have to use tin snips but my snips seemed to roll the edge over too much. They didn't cut clean like the scissors did. Well worth the time to get it done though. I made a holder to hold the clutch while a guy is trying to get it apart. Then I made a special wrench to fit on the spider. It took a 30" snipe to get the damn thing apart but I didn't bust anything!!! I looked on the threads and there didn't seem to be any thread locker on them but man was that thing on there. I can see how the stealer could have broken it.

 

Mastrblastr, I was going to go with oilite, but bronze is what my machinist had on hand. Also had him take the grooves out of the faces and take a bit off each sheave, spider, cover plate, etc, turned out real nice. I'm always amazed by what a truly good machinist can do. Have a look in my link at the primary holder I built, lol, looks kinda funny but works great. Think when I have it off next, I may try your shim trick on the buttons too.

 

589650, that clutch holder is the bomb dude!!!!LOL!! As long as it works, who cares!! I built one out of 1/4 inch plate that I can put in a vice. Works good. The spider wrench I built is on the same idea as yours but a little more elaborate.

 

MB,
Nice job you should show your pics of your clutch breaking tool.

 

589650, what up with the prairie?

those tools will do the job. do you have an overhead picture of the spider wrench?