My son's 2003 LT started slipping the clutch so bad that it will not move under its own power with him on it. I have taken the side panel off and it appears that the rear most clutch is slipping as the metal drum is getting very hot. How do you go about adjusting this to stop the slipping? I have not bought a manual yet, but most likely will do so today. I am looking for any hints or clues to how to properly set this up. Thanks in advance.

Ken

 

Welcome to the forums. [img]i/expressions/face-icon-small-smile.gif[/img]

I recomend pulling both the front and back clutchs off. It's time for maintenence while in there.
Front: take sliding face (variator) apart. Clean the old grease out and check for flat spots on the rollers, grooves where the rollers run and grooves on the plate that covers the rollers. I only use a dab of grease on each roller as opposed to packing it like Suzuki does.
When re-installing, make double sure that the keyway is in the correct place.
Rear:Check the bearings. Lightly sand the rear clutch pads to remove the glaze. Also check the pads for wear as this may be why it's slipping. Work the sliding face back and forth to see if it's sliding easy.
We'll go from there.
FYI: an impact wrench is needed to get the clutch nuts off. They are right hand threaded (righty-tighty). LOL

 

It took me several weeks to get the parts and get around to putting it back together. Upon reassembly I came across a large flat washer, maybe 1" or bigger that I have no idea where it goes. My factory service manual does not show its location either. Looking at it, it appears that it might of come from between the two front driving faces on the front clutch? Any help would be appreciated.

Ken

 

the washer does between the front faces on the end of the spacer, lt80 recominds replacing it with the old style longer spacer or grind down the washer to the same size. It is supposed to give more take off i think, lt80 is the man on these things so we will see what he says

 

I didn't see a keyway , just lined up the splines and rollers. Did I miss something?