Chaincase chain rubbing housing JD 400

[Curlymurt]

So if you take the secondary clutch back off, you can't tap the shaft more the chain case side?

If you hold the upper gear in place on that partial shaft against the spacer, is the chain perfectly vertical then?

Nope. It doesn't go over. There's about an inch gap from the end of the threads to the outside of the chaincase. On the secondary side, everything is flush and tight.

I should have measured the shaft while it was apart, but it appears to be about 8.75" long. It seems too short by the length of the spacer, 7/16 of an inch. Nonetheless, I don't have 7/16 to gain on the secondary side.

[Curlymurt]

Also, that shaft should not be sticking out past the end of the secondary like it is, so it's definitely too far over.

It doesn't stick out at all? I assumed that was the reason for the spacer washer... So the spacer washer would push against the secondary to keep it tight.

Edit: it's partially the photo angle. Here's one looking almost straight at it.

[Matt]

Think you missed something I typed before - that shaft is NOT supposed to come to the end of the secondary! There is always space, which is why the secondary bolt is always long to reach in. Now that I think about it I have no idea why that is, but every sled I've worked on is like that, it must have to do with the operation of the clutch. I'll try and get a picture.

[Matt]

From my 400:

[Curlymurt]

From my 400:

Well, I'll be damned.

So I need a new bolt bc that's not what mine looks like. Do you have the length of it? Mine is only 1 1/4". And is that spacer washer full? This one has a large enough inside diameter that it slides over the end of the shaft

Edit: The secondary shaft bolt might be long enough after all.

[Curlymurt]

This hard rib is where the bearing stops... It also prevents the shaft from sliding further into the case.

Edit: All is right in the world. I filed down the rib ONLY using the edge of a fine file. That allowed me to slide the bearing further onto the shaft. I now have about 7/16ths of the shaft inside the secondary!

I'm still curious about the washer though on the right hand side... Is the inside diameter of the washer as large as the shaft or just large enough for the bolt?

[jep_800]

I'm not sure which secondary that is on your sled, as it appears to NOT be a Comet 90D. Here is a good shot of what the end of the secondary looks like on my 800, with a long bolt (which reaches inside to meet the shaft threads), a washer, and a black cap that fits over the end of the secondary. I'll try and take a better picture of it tonight, as I have one taken apart on my bench.

It looks like a secondary meant for another sled, cause I thought all Mid-mount sleds used the 90D if they have been Comet upgraded.

[jep_800]

Here is a closeup of the 90D without the cap and bolt on the end. From what I could see, your secondary doesn't look like this.

[jep_800]

Also, your previous bearing appears to have worn the shaft down just after your splines. That's why there was a rib there... shouldn't be there.

Here is a picture of one that was removed (don't ask me why the old splines are curved like that... not sure), and next to it is a NOS one that I acquired and installed in my X8. You can see the diameter of the shaft should be the same throughout the shaft directly after the splines.

[Matt]

Jason, I have seen the same thing happen on another '75 JDX8 shaft. Power!!!!

He has the Salsbury clutches. Normal for a 400. They weren't in the replacement program.

[Matt]

Edit: All is right in the world. I filed down the rib ONLY using the edge of a fine file. That allowed me to slide the bearing further onto the shaft. I now have about 7/16ths of the shaft inside the secondary!

I'm still curious about the washer though on the right hand side... Is the inside diameter of the washer as large as the shaft or just large enough for the bolt?

ID for the bolt, then the OD large enough to cover the end of the clutch.

[Matt]

OK, just looked at your other post and saw you have a 100 or 101 Comet primary clutch, so Jason is right, this is the wrong secondary for it. They are supposed to be replaced together.

[Curlymurt]

I'm just getting caught up here... Yes, those are interesting developments and your suspicions are confirmed. I did some part number digging and it appears I still have the secondary from a Salsbury 780, 850, 910, or 1190... I dunno. It is from at least the 1190.

Also, yes, the bearings are slightly looser in one spot than the rest of the shaft, but barely. It actually cleaned up decently, but I'm sure I'll loose a little oil under a bearing. I'm just going to install a retaining cap screw, two washers, and torque it to 20 ft-lbs per the manual. Based on the last couple of years around Indy, I probably won't ride it enough to do much more damage. If it blows apart, it'll be a fun story. (I don't condone this)

At least now I know I'm probably not running an optimal setup due to the primary and secondary not matching up. That also probably explains why it had two different sized belts when I picked it up.

[jep_800]

They're always a mystery especially when someone has modified or changed something that may not have been common to the sled. In this case, Matt is correct, and that's why I brought up the Comet 90D, cause I also saw you had a Comet 100C primary clutch. When those replaced original Salsbury clutches, they used 100 or 101C primary and 90D secondary.

If you are interested, I found a replacement secondary shaft from Certified Parts Corp. This is a parts company that gives JDsled members a discount on parts. Sometimes they have things available that others do not, so it's worth investigating. I don't even think I paid much for it. Less than $50 I believe. Their number is: (608) 752-9441 or DianeJ@CertifiedPartsCorp.com

You'll have to give them the correct part number from the parts catalog and they'll let you know if they have it in their inventory.

Since I said I'd show what that bolt and cap look like, here they are.

Jason