I just got done getting the engine together and decided to pull apart the front clutch assembly to do LT80's recommended mods. Well after I got the ten pounds of grease cleaned off I realized I had a missing part. One pf the U shaped plastic dogs is missing off of the spring plate that sits against the rollers (the second part you pull out after removing the cover, there are three of these). Is this going to be a problem? Can I get by with just the other two? The other thing I noticed was that two or three of the rollers were laying in there wrong, how can I keep them from wobbling out of place other than using a little moly grease? Thanks for your help, it is appreciated.

 

The plastic u-shaped piece is a guide to prevent metal to metal contact when the clutch moves, I would replace it, the dealer should be able to get them. If you found some of the weights laying wrong,the plastic around the metal weight is probably worn, it should be wide enough to stay in the groove without getting stuck or rolling out. I made new sleeves for mine, the old rollers had flat spots in the plastic from getting stuck in one spot. You should be able to get new rollers if you don't want to make your own ( I had access to a lathe and turned them to match the old plastic parts).

 

Did a search and wanted to give you guys info.

My buddy's daughter's LT80 made some serious noise the last trip.

Here is what he sent me by e-mail:

Just got a call on Madison's quad: the front clutch rollers were worn flat.
They couldn't tell me why it happened. They said it was the first one they
every had that problem with.

$217.00 Ouch!



LT80 - Thanks for the help. If anyone ever does this work and could take some digital pictures that would be worth a 12-pack from me. I have a 2001 and have heard this is a problem for this model year and would like to know how to do it. Thanks.

 

Yes you need to replace the plastic horseshoe. The rollers are all over because thats what happens when you pull it apart.It doesn't mean it was running that way.
You place a small amount of a high temp grease on each roller when re-installing,that holds it in place durring installation.It also gives it a lil lubrication.I use about 1/10 of what Suzuki puts in.If there are flat spots on the roller,get new.
PM me with your address and I'll send you a complimentary horseshoe [img]i/expressions/face-icon-small-happy.gif[/img]