Ok, finally got a break from the heat/humidity and a chance to finish the clutch. I disassembled and cleaned the rear clutch and reassembled including the new buttons and turning the helix 1/3 of a turn before putting on the snap ring.

I put the spring in the middle hole on the pulley side and the 2 position on the helix which is where they were.

I got some threaded-rod and removed the front clutch and cleaned it up. Neither the rollers nor the weights appeared to have any flats so I just blew them all off with brake cleaner and reassembled.

I put it all back together and it worked! Put the cover on and took it for a drive. It seems sluggish to me now. I have become quite used to the power and quickness of my 800 Sportsman so that could be throwing off the "seat-of-the-pants" feel. But even the wife mentioned that it seems "sluggish".

Anyone have any ideas as to why it may seem "slow" now? It has the blue spring in the front. Did I assemble something incorrectly? Should I look into any mods or consider a clutch-kit? I can get it to about 50 on the top end ( couldn't hit 45 before) but it takes about 200 yards to get there on a surface street.

Any "common" things that people don't do or forget to do when reassembling the clutches?

 

Just a follow up. Even before this clutch issue this machine would seem to almost misfire on steep hillclimbs. Not a backfire, not a true miss but something that would cause a loss of power. It would get you to the top of the hill, but your heart was in your throat the first time it ever happened.

So, I pulled out the carb and jetted it down from a 172.5 to a 165 and VOILA!!! This machine seems to run great now. We rode a few weeks ago and it climbed even the steep hills with ease in high gear without the "misfire" issue which now can be contributed to too-fat jetting!!

Thanks for the help guys and many happy rides!!

 

Glad to hear you got it running good.