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  #1  
Old 05-03-2016, 01:41 PM
Weekend Warrior
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Join Date: May 2016
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Default LT80 Secondary clutch rebuild

The secondary clutch on my 87 LT80 is in rough shape from years of sitting. Can anyone point me to a shop for a rebuild? Would I be better off purchasing a new secondary? I'm located in NJ, east coast shop would be a plus.

Thanks,
Mike
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LT80 Secondary clutch rebuild-20160503_150431.jpg   LT80 Secondary clutch rebuild-20160503_150450.jpg   LT80 Secondary clutch rebuild-20160503_150405.jpg  
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  #2  
Old 05-03-2016, 08:53 PM
Extreme Pro Rider
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Welcome to the forums Mike.
Kawasaki
Yours may be able to clean the faces but I bet both bearings are no good. I'd prolly replace it all.
The rear clutch pack is good tho (the contact shoes). FYI: big nut is left handed.
I think you need to get into the front clutch if you haven't. Prolly needs attention and maybe parts too.
I may have some used here.
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Old 05-05-2016, 07:16 AM
Weekend Warrior
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Thanks for the link LT80. I'm going to order new sheaves, they also look to be bent. I'll also get the bearings, anything else that is a typical wear part in the clutch? I don't have the primary clutch with me to see whats worn out on it. What are the typical parts to be replaced in the primary?

I see a pair of clutches for sale on ebay. They are only a few miles from me, I might just snag those.
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  #4  
Old 05-05-2016, 07:24 AM
Extreme Pro Rider
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What happens in the front is that the Suzuki grease gets hard and limits roller travel even to the point of ruining the variator. The rollers will have flat spots and the plate that covers the rollers will be bad (if the grease got hard).
Prolly bad rollers anyways.

Rear clutch: You will either have to order the lil snap ring that holds the small bearing in or get the one out of the parts you have. I use hemostats to get to that snap ring.
FYI: belts wear forever.
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  #5  
Old 05-05-2016, 07:35 AM
Weekend Warrior
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My belt was so dry rotted that it snapped when I was trying to get it off! Is there a specification for the grease on the driven rollers? I cannot remember getting the clutches serviced, i'll assume the grease is hard and the plate is shot.
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  #6  
Old 05-05-2016, 07:54 AM
Extreme Pro Rider
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Most any grease will do.
I only use a dab of grease on each roller. And that's just to hold the roller in place durring installation.
The newest LT80's didn't use any grease.
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  #7  
Old 05-12-2016, 07:17 AM
Weekend Warrior
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Hey LT80,
I got my hands on a used Secondary clutch, the sheeves are in better shape than mine but the shoes are worn out. Whats the best way to get the large nut off of the secondary? Impact gun?
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  #8  
Old 05-12-2016, 08:16 AM
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Yes, impact gun.
FYI: big nut is left hand thread.
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  #9  
Old 05-12-2016, 08:22 AM
Weekend Warrior
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Thank you with my left hand!
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  #10  
Old 05-12-2016, 10:38 AM
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Lol
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