Also wanted to add that the faces of the buttons as well as the helix were still smooth and it was wearing nicely

 

Now i get it. It is shutting too far, because the movable sheave gets too far from the helix and thus sticks shut. I guess when i was trying it with my hands it feels like the helix moves, but it doesnt. Yes, it took me a bit to catch on lol

 

Shouldn't be knocking off the tops of the buttons and locking up.Plus I guess you're using the old style 5430766 buttons. Not sure if the white ones for later models work that well.Haven't tried them. Plus look back over the clutch preloading steps. It might be something that you're not doing right.

 

Yes those are the buttons i received and bought initially. We noticed there was quite a bit of movement when the helix was installed without the spring, so we could mock it how it would sit. We added a spacer between the helix and snap ring to almost rid all slack. It is working again, so hopefully that will keep the sheaves from opening too far and allowing the helix to jump up. So i guess round 10 is at progress and we will see how it does on the trials and in the mud tomorrow

 

The original was more of a shim than a washer that went before the circlip. Hope the washer helps on this go round. If not chunk the helix.

 

Yes, that is what we were thinking, since as the clutch wears it needs more shims to take up slack. I am going to ride now so we will see how it does under a load....

 

As Mel Brooks said: May the Swartz be with you...

 

Hey maybe that worked better! I simulated several types of driving, especially idle to wot, since that is where the helix would jump. Last time it only took one mud hole, this time I got it through several sticky ones, and once i got in at low rpm, I hammered it. Those new tires made a huge difference too, which is nice. Hopefully it will hold in the long run, so I guess we will see. Thanks for all the help OPT! Even though I still haven't replaced the helix I think you will learn to forgive me... maybe.

 

What's to forgive? Ain't my atv, I don't have a dime invested in it.. I just have fun seeing other people work and not me.. Hopefully that thicker washer does the trick. If it doesn't,oh well a helix is easy to swap out..

 

lol true. I hope so as well.