Secondary clutch rebuild questions

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pete

New member
I'm rebuilding my secondary clutch on a 2004 Polaris 700 classic. First, if someone could confirm the difference between the TSS-04 and TSS-98 is the 04 has 4 bolts holding the helix and the 98 has 8? I have 8 bolts.
1) When I was taking the secondary clutch off I noticed it slides back and forth on the shaft about an 1/8". I didn't notice this before, is this normal? The hold in bolt was tight.
2) Is there a trick to installing the moveable sheave bushing? It is a pressed fit and the sheave material flexes pretty easily. I'm afraid I will damage it if I press to hard to get it back in.
3) I was thinking I would rebuild the primary clutch too. I went on Team Ind. website and I believe I found the kit for my sled, but if I could determine if I have "wide rollers" that would positively identify the kit number (940153). Does anyone know how to distinguish wide rollers or not?
Thanks, Pete
 
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snow_monkey

New member
I belive you you should not have that movement. I just took mine off and it was tight. There are a number of washers behind it when you remove it. The only other thing that could of happened is the key was outta place when it was assembled.
 
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sleddog66

New member
Actually it is good to have some play back and forth on the shaft. Make sure to have the correct offset to give you proper deflection. Can not remember the play spec, but about 1/8 inch should be close
 
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RMKrick

New member
Ya it needs to have alittle play in and out.After you take it off ck the shaft sence your right at it to ck your jack shaft bearing.
 
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Snowchick

New member
i believe the difference is between the 2 part numbers is that one helix has the reverse notch and the other does not, and can not be used on a sled with reverse.
the helix is bolted in and comes out with out any loaded pressure from the spring. unbolt and twist the helix and it will come apart. the spring is loaded from inside of the of the clutch with cir-clips and washers.
the side to side movement is normal. all polaris's have this slight slop.
good luck rebuilding this clutch, it is the worst piece of crap i have ever seen. i had a 2004 with 7000 miles when it failed. i rebuilt it and it did not last 250 miles. so i bought another used secondary and it failed with in 500 miles. webought a new secondary and sold the sled since, so i have no idea if buying a new one is the cure or not.
 
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pete

New member
Good info snowchick!

Snowchick said:
i believe the difference is between the 2 part numbers is that one helix has the reverse notch and the other does not, and can not be used on a sled with reverse.
the helix is bolted in and comes out with out any loaded pressure from the spring. unbolt and twist the helix and it will come apart. the spring is loaded from inside of the of the clutch with cir-clips and washers.
the side to side movement is normal. all polaris's have this slight slop.
good luck rebuilding this clutch, it is the worst piece of crap i have ever seen. i had a 2004 with 7000 miles when it failed. i rebuilt it and it did not last 250 miles. so i bought another used secondary and it failed with in 500 miles. webought a new secondary and sold the sled since, so i have no idea if buying a new one is the cure or not.
Click to expand...

When you rebuilt the clutch did you replace the moveable sheave bushing and if so, could you explain how you installed the new? Thanks, Pete
 
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Snowchick

New member
the brass bushing is what goes bad.that allows the movable sheave to run not parallel to the fixed one. i could not find a actual replacement bushing. so one day i was messin around at work ane tried making a couple from brass. and was unable to get any longevity from them. so i broke down and bought another clutch. it failed with in 2000 miles.
 
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sleddog66

New member
A dealer can get you the large brass bushing. I have never had much luck with clutches beyond 2500 miles, even brand new.
 
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snowbuff

New member
The TSS-98 was TEAM's first version of their clutch and came out in 1998. The TSS-04 was the next version and came out in 2004. The '04 has less bolt holding the helix to make it easier to change positions. Plus the '04 has a smaller hub to allow the belt to go deeper for better top end.
 
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Snowchick

New member
i stand corrected; float not slop..
lot of good info in the link, thanks.
i must be the exception here though. i had a 2002 XCSP and it had 11000 miles on its secondary without any problems. i do normal routine maintenance yearly and prior to every ride on both my sleds. unfortunately my 2004 XCSP had the Team secondary and did not get the same results. just had too many problems. i have since sold both sleds and now i have 2009 600 switchback and 600 Shift. they both have the same team secondary. no telling what will happen until i get some miles on them....







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