I was wondering if there is supposed to be any play in the primary if you grab it by the sides and move it back and forth should there be any play in it there is a considerable amount in mine 620 km on the 04 700 belt needs to be shimmed as well did not think this would have to be done majority of riding is on trail 25% mud rest is fairly good trail I use low range when travelling below 30 km/h most of the time any help would be appreciated

 

Just did my 2002 650 primary clutch. The bushing in the clutch cover is prone to wearing out quicker than the bushing in the movable sheave IMO. My outer clutch cover bushing was way out of spec whereas the bushing in the movable sheave was still pretty good. I made new bushings out of oillite bronze and pressed them in. I shimmed my wear shoes with some .006" brass shimstock to get the wear shoe side clearance back to spec and put it all back together. Works like a hot damn and it's as quiet as can be. I'd check the bushing on the outer cover first and see how bad it is, as you can get that one done without having to pull the clutch off the bike. If it's out of spec, you can get any good machine shop to make a new bushing and save yourself the cost of buying a new cover (as Kawie doesn't have a replacement bushing for the cover.) If you get a machine shop to build you a new bushing, mic the shaft that the bushing slides on and get them to machine the new bushing I.D. about .0015" bigger so you have some clearance. Make sure everything slides beautifully before you put it back together. You'll be amazed how much quieter it will be!! Hope this helps.