Newbie here. Been surfing this forum for about a year and now I'm stumped with an issue I can't find a thread on. I bought a late 90's LT80 for my kids last year that was non running. After the repairs and updates it ran great all summer. Just recently my son was on it and it wouldn't move. Engine sounded fine and revved up without issue but it wouldn't move. Opened up the case and the rear clutch shoes / pads were toast and the front clutch had flat rollers and was full of the grease cement everyone talks about. The new rear clutch was installed along with 4 new rollers in the cleaned out front clutch. I tested it out and still no movement. I ran it with the side case off and noticed the front / primary clutch was not engaging. The moveable drive face on the front clutch is not moving. Since the clutch is not engaging the belt is riding on top of the spacer washer tearing a groove into the belt. I'm embarrassed in the amount of time I have invested already but I'm not about to let this thing beat me. Below I listed additional repairs and info on the machine since I've had it. Any help will be greatly appreciated. Thank you

Rebuilt Upper
New Battery
New Belt
New Tires
Cleaned Air Filter
New Carb
Boysen Reeds
New Stator
New Rear Clutch
New Rollers Front Clutch
Eliminated Oil Pump
New Petcock Valve
Repacked Exhaust
Compression @ 125

 

The front clutch hub the roller tracts were not gouged from her rollers spinning?
Sounds like something isn't together correct.

 

I agree. Either something isn't together correct or one of my parts doesn't have passable wear. I ordered a new movable face plate last night because the old one doe not have the notch in the center and lays on the rollers a little uneven. Seems off for some reason. The clutch is. assembled as the diagram is mapped out. I'll take some pics of my parts to show you the condition.

 

I'm following the assembly diagram so I'm thinking one of my parts doesn't have passable wear. I bought a new movable face plate last night because the old one does not have the alignment notch in the center and it doesn't sit even on top of the rollers. It just seems off to me. I will take pics of my other parts and post them.

 

 

It sounds like that plate is wrong. Even smashed, you would see the key notch in it. Is the key there? Without the key/notch only thing keeping it from spinning is the tightness of the nut. Weird.

 

There is no key notch. There was a metal lip on the inside of the plate that I smoothed out with a dremel but no key notch. Curious what the key lines up with?My shaft does not have anything for it to align with.

 

A key holds the starter gear from spinning. The key also sticks out from the starter gear a small amount. The notch on the roller plate aligns with the part of the key that sticks out..

 

I have not seen a key coming out from the starter gear. Any models made without the key?

 

Nope. Pull the starter gear. A key (prolly beat up) will be there.