Bubba,
My brother helped this guy tear the primary clutch down tonight and he said that the primary spring was not bringing it all the way back out. Could the spring be worn out? It makes sense to me, but just wanted to be sure. My brother said that he could push the clutch out another 3/4 inch and then it would run fine, no dieing when putting the brake on. Should they replaced the stock spring or get a stronger one?

 

Lee, tell them to take the belt off, then remove the outer cover off the clutch. They should be able to freely slide the outer sheave in and out without any problem. The spring is either broke on one end, or something is binding. If it has the blue/green spring, you could put a white spring in it, but no more. Any later model sport or scrambler will have a white spring factory in it. I think you might find a broken spring. Let me know,Bubba

 

They told me the spring wasn't broken, it would just not return the sheave to its starting point. They took some fine emory cloth and smoothed up the shaft but it still did the same thing. They think the spring may be worn out. It is 16 yrs. old. Would the white spring be better? or just a new stock one?

 

If the spring is a blue/green, put a white one in it. It will give a little more engagement rpms' but that will help the problem. Sounds like the clutch is just plain worn out. Make sure they blow out all the old belt dust (looks like brake dust) and make sure they dont use anything to put back on the clutch. Bubba

 

Bubba,
He is going to put the white one in. Hopefully that will get it working good enough to sell. Thanks for all the help. I will PM you in or 4 weeks and run some ideas by you about my xplorer.