I am going to try a different main spring in my 500 HO, where can I get a diagram for this??? Mech. said something about
6-7/16" bolts and 1-5/8" bolt, and to make sure "x's" lineup???????HELP!! Thanks.....okie

Nevermind......did it...pretty easy!!!!!!!!

 

Can you give us a run down of what all you had to do? Do you need a clutch puller tool to do this. Never changed my own but if it's that easy I'll start. My mechanic has been telling me you have to use the clutch puller.
Help???

 

Mudislife,
This should guide you through the process.

3. For primary clutch installation it is not necessary to remove the clutch from the machine. Remove the belt, then the center bolt being careful not to lose any washer(s), O-ring(s), or spacer(s). Replace the stock washer and replace with the supplied HSP washer. Remove the six cover bolts in a criss cross pattern (USE CAUTION. COVER IS UNDER SPRING PRESSURE). Once cover is off, remove the stock primary spring. Next, using an allen head and socket, remove stock primary weights and replace with the supplied HSP weights. Install the supplied hot seat primary spring. Reinstall the clutch cover tightening the bolts in a criss cross pattern making sure the X’s on the cover and the clutch spider are lined up and torque to 7 1/2ft lbs. Reinstall center clutch bolt and torque to 40-ft lbs. It is also a good idea to inspect the rubber seal on the rear clutch housing, behind the primary clutch for damage and replace if necessary.

4. For secondary clutch installation you will need to remove clutch from the unit. Remove the center bolt, making sure not to lose any washer(s), spacer(s), or O-ring(s). In most cases the clutch should remove easily from the shaft. If it does not, you may need a clutch puller (available from HSP).

5. Disassembly and reassembly of the secondary may be easier with someone to assist. From the helix side of the clutch on non-EBS models, grab the sheaves (ONE WITH EACH HAND) and rotate them against each other ¼ of a turn and hold with one hand. Then with a rubber mallet (GENTLY) tap the helix down ½ inch. Now using snap ring pliers, remove the snap ring and gently release the two sheaves. On EBS models there is no need to rotate the sheaves. Simply push down firmly on the helix and remove the snap ring.

6. Next remove the stock helix and spring. Carefully inspect the secondary clutch buttons and replace if excessively worn. Now on non-EBS models with an assistant, reinstall the supplied HOT SEAT spring and helix in the recommended holes (see Page 1). Once the spring is in place, push the helix down ½ to ¾ of an inch until it engages the spline. Then rotate the moveable sheave counter-clockwise 1/3 of a turn and hold it. Now push the helix all the way down on the spline and reinstall the snap ring.

7. For EBS models reinstall the stock secondary spring and the supplied HOT SEAT helix. Simply push the helix down far enough to reinstall the washer and snap ring.

8. Reinstall the clutch on the unit and torque to 17-ft lbs. Reinstall the belt so the numbers are right side up and are easy to read. Before putting the housing back on you will want to double check various tolerances such as clutch offset, which should be 5/8 of an inch. Belt deflection should be no more than 1-1/8 to 1-1/4 of an inch. FOR OPTIMUM PERFORMANCE, MAKE SURE THE DRIVE BELT IS IN GOOD CONDITION.

9. Now reinstall the clutch housing, making sure that the foam rubber gasket is in the proper place so that no water leaks can occur. Reinstall the rubber exhaust boot.

10. Do not forget to tighten all fender bolts or footrest bolts that may have been loosened during disassembly.

 

Thanks!!!!!!!! That's exactly what I've been looking for.
Great Post!

 

Stinky, how much do you know about different springs? It sounds like you know alot....I have a question for you.....right now on my HO, I have a HPD kit, with stock prim spring and gold secondary. I had a blue prim spring but it took forever to engage and when it did it was all or nothing. I am looking for more "low" end power in HIGH gear. Would the silver/blue spring help instead of gold?

Mudislife...I am pretty green and it only took me 10-15 mins. If you want instructions up to the point where Stinky started, let me know. Thanks guys for a great forum.

 

90 ft-lbs on the 6 cover bolts is way way way too much. You will strip them out. That must be a misprint.

 

Okie, I would like as much info as I can get. If you have more I would love to see it. You can post it here or e-mail it to me jsvo1@yahoo.com.
I would like to see each step you had to take to get it done. I will only be changing the primary spring. This is my first time and I really don't want to screw it up.

 

Okiedude,
That was an install guide which I cut of the HSP site a while ago,
I know a bit on the different springs, but prob not as much as the pro riders in this forum. Im quite a newbie to this forum also.
When I was trying to setup my clutch, (Elroy) in this forum helped me alot & explained all pros & cons of different weight & spring setups.

I think personaly that with a silver/blue secondary you will loose alot more than 10% top speed,
but it might pay to give Darryl @ HPD or Rick @ RitterCycle a call.
Rick was very helpfull when I called him about buying springs, he asked what I wanted my bike to do, I told him & he sent the exact springs to suit my riding.

 

On the 6 cover bolts, it's 90 in lbs (equal to 7 1/2 ft lbs) not ft lbs. You will strip the threads.

 

First let me say again that I am not a mech. in ANY way. Mudislife, it is real easy, I will try to type what I did:

1. Remove the 4 phillips head bolts and locknuts that bolt bottom of footwell down to frame.

2. There are (I think) a total of eight 3/8" head screws that hold cover on, remove them (1 will hold the fuel filter also).

3. Cut (if you have another one to replace it) the zip tie that is around the clutch cover exhaust tube at the top of the cover. If you dont have another one, well get one!

4. GENTLY pull the footwell out away from the quad and hold it while you GENTLY wiggle the clutch cover out.

5. Bingo...you are at the clutch.....stinky's instructions take over now.

Some notes.....you DONT have to remove belt to change your primary spring. Just remove the 6-7/16" head bolts and then CAREFULLY remove the 1-5/8" bolt (IT MUGHT BE UNDER TENSION). There is a "X" on the metal clutch cover that you are taking off, make sure you line it back up with the "X" on the clutch housing(?)



Mudislife, what color spring are you thinking of putting in? The shop here tweaked mine out so much that HPD says the primary spring they put in was not theres! It is a HUGE blue one and they dont sell a Blue primary for the EBS. This spring is like a garage door spring!!! JK.... let me know......okie