Service manuals

[Kyle T]

Here is the 87-92 LT250R service manual.
Here is the 87-90 LT500R service manual. Click on the download icon on the right of each section.

[Kyle T]

Well, the LT500R manual isn't working, so I will be your manual. Ask me something and I'll post what it says in the manual ASAP.

[2StrokeJunkie]

I have a 88 Quadzilla and the clutch basket went bad, so I purchased a Hinson clutch basket, after I put it on and installed the inner clutch basket with shims it will not longer spin freely. My question is if you have any suggestions as to what the problem may be and also was is the torque specifications on the basket nut. Thanks for your help.

[Kyle T]

The basket looks just like this, correct?

Do you have one shim on the inside of the basket, and one on the outside of the basket?
The inside of the basket (where it says "BILLET PROOF") to the outside of the kickstart section of the gear (where the bearing rides) should be about 31mm.
Also, the clutch nut takes 43.5 ft-lbs.

[2StrokeJunkie]

Yes that is what the basket looks like, I did the measurement and it is 30mm, and I do have a shim on the inside and outside. When I tighten the nut to 18 ft-lbs, it will spin freely, but once I tighten more than that, it will lock up. Thanks for any input.

[Kyle T]

Are you using the stock shims and nut?

[2StrokeJunkie]

Yes the shims and nut are stock.


Could the inner bearing or sleeve would have any effect on this problem?

[Kyle T]

That's what I was just going to ask you about. Measure the clutch bearing sleeve. It should be about 27mm long. Also, measure the bearing. It should be about 26.6mm long.

[BadAss88GT]

Got a manual for 85-86?

[Kyle T]

Yup.

[2StrokeJunkie]

The bearing measurements match what you said.

Could the inner basket be the cause of this problem?

Any other ideas would be greatly appreciated....I am running out of ideas...

[Kyle T]

Measure the splined part of the inner basket. It should be about 18mm thick.

[2StrokeJunkie]

I rechecked the torque on the bolts on the back of the basket and realized that they were torqued too tightly...So I changed the torque to 9 ft-lbs...and now the center hub will spin, but with resistance at 45 ft-lbs of torque...should this spin freely (like a bearing) or should there be resistance (there is quite a bit of resistance). But it is not locked up like it was before.

[Kyle T]

Try 43.5 ft lbs and see if it still has resistance. If you still feel resistance, remove the clutch assembly and measure the length of the countershaft that sticks out of the case. It should be about 60.6mm long.