Comet Clutch talk

[jep_800]

Since restoring my 75' X8, I've had a plan to rebuild a couple of clutches I have acquired. I installed a fairly nice 100c with new weights & spring, and it had recently gotten a new set of rollers & buttons. This clutch replaced a pretty worn out looking 102c which was on the sled when I received it.

I had been discussing this topic with Brian Linder for a while now, and reviewing his old threads on how to rebuild said clutches. So, like most of us, I've been stockpiling parts over the years, and started going through my bins to see what I had. Looks like I had all the correct kits to begin the rebuild of the 102c. I had finally gotten done building a holding tool for the fixed face. I did a mockup and gave it to a welder I know, who put it together for me. It's not an original thought as I had seen a guy do something very similar while rebuilding a Polaris clutch... don't reinvent a wheel if you don't need to.

[jep_800]

There are common parts that everyone does while building these clutches, such as: new pivot pins & washers (preferably the bolts w/ nuts), the rollers w/bushings, the buttons, new spring, and new fly weights if your old ones are shot.

The upgrade to a 102c is the fact that there are two bushings which "should" be replaceable as they are a man-made material instead of brass. I suppose those items could be replaced as well, but seems like you'd probably spend more time and money trying to accomplish that then just getting a newer 102.

The first bushing I replaced was the staked bushing in the cover plate. When discussing this with Brian, it seems that not many have tried to replace this. I wasn't sure myself, as the detents that hold the bushing in were probably punched after the bushing was put in place by Comet.... so maybe they weren't meant to come out.

[jep_800]

So I chose a socket that fit directly over the bushing, but smaller than the opening in the face plate. I put a little heat to it in order to warm the metal, just hoping that this might loosen things up a bit. Placed the cover over an open set of jaws on my bench and starting tapping firmly (top down). Took a bit but finally started moving out the bottom. Before long it was out. The NOS bushing was tapped in the reverse order (tapped from the bottom of the plate). This bushing looked a little different than the original (original is removed sitting on top of the plate), and found out it was made by Roetin for Comet. (Comet bushing #211286 (NOS), replacement #211286A).

The positive to accomplishing this is the fact that we can save the original face plates which have the JD logo and name stamped in. The alternative is getting a new face plate from Comet, but as I understand it, getting approval to stamp a JD logo is not forthcoming.

[jep_800]

The next bushing proved to be more challenging. It is the larger bushing on the moveable face that is made of the same material. The difference is this one has a locking ring that sits in a groove. I originally was going to try and press this out, but Brian said that probably won't work due to the ring, which I agreed. So, the best bet is to try and cut a couple of sections out of the bushing and hit it with a punch to remove it in sections. This was done, but the bushing did not want to come out easily. (Comet bushing #204280 (NOS), replacement #204280A).

[jep_800]

The next step is to try and get the replacement bushing in the face. The key is to try and hold the ring tight to the bushing groove so you can get it past the face in order to tap into place. I first tried a tape material that is meant for stopping leaks. This is a strong rubber material, but very flexible. Didn't hold tight enough. The next attempt was a zip tie of the right length to hold the ring. This did work. What I didn't know was how tight the bushing would fit in the opening. It went in good for a while, but started to bind up and I eventually mushroomed the end of the bushing.... Shot!

I think it is best if you can find NOS vs. the new replacements. I think that they have a better chance of going in a bit easier. So, found and ordered a NOS 204280. I also sanded down the opening more, and will maybe try a little heat next time. Hopefully better results. I will post again and pray for success.

[jep_800]

Just a little more work done was to the fixed face. The hub on a 102c went back to solid steel, and they are usually pretty rusty like this one. A little time and polishing gets them looking much better, though not new.

[DinosaurDan]

Hi Jep, just a little suggestion on installing fiber bushings, it is much better to press the bushings into place instead of driving them into place to avoid mushrooming the bushing. if a press is not available you can use a vise as a press to push the bushing into place with a socket.

[jep_800]

Good suggestion Dan. Yes, I think that will probably be the case. I think going slow is also the key, as the ring may need a little tapping into place as you get close. This could probably be done inside a press as well.

The face plate went well tapping with a socket of the same diameter, but I think the NOS bushing had tighter dimension tolerances. The replacement 204280A just seemed too big for the opening, which could have been part of the problem.

[harleysportster]

Place the fiber bushing in the freezer overnight. It will shrink it enough to ease installation.

[sledhead16]

All good points and a great topic to discuss. I've learned that clutching is more time consuming than anything but tricks help alleviate some of that!

[jep_800]

The second attempt at install of the movable face bushing went much better. I think a little more time and preparation helps, so I advise taking your time if you want to replace one of these.

This bushing was also made by Roetin, and was listed as NOS. They are a very snug fit, compared to the old bushings which had quite a bit of play in them. This should definitely make this clutch last a long time.

[jep_800]

Installed the spider to the proper spec, new buttons, new rollers & pins, new white spring, and secured the cover plate. Everything moves as it should. The plan is to remove the 101c off the 800, install the 102c, and begin the teardown of the 101.

Jason

[sledhead16]

Looks great! Your freeze the bushing then? And then press it in?

[jep_800]

Yes, plus a bit more smoothing of the opening with fine grit. Still a little tricky trying to keep the ring flush with the bushing when it is pressed.

[400brian]

So what it comes down to is: If we had a source for the cover bushings like Jason found, we purists could keep our JD logo cover plates. New Comet stamped covers are a tad over $50.

Roetin was sold 10 years ago. Pics of the new Comet covers appear to show a different bushing.

Rainville has a contact at CPC, at this point it seems the logical place to start.

Guys, is there any interest in pursuing this?