Well my brother and I went out for another ride up one of our regular places today (sourbie).
We didn't make it very far. After a real long straight there is a very sharp 90' turn to the left and up.
He was part way up dead in the water. Engine was still running but had no forward go. We coasted it to a flat spot about 30 yards away. After a close look we see the clutch had come apart and two of the pucks on the 94c were missing and it was jammed open. We looked for the missing pucks with no luck. I didn't expect to find them anyway but we tried. At that kind of rpm they are probably still orbiting our planet. To bad because my brother said it was running like a rocket. I had just changed out his 42mm power jet carb and put in the 38mm Mikuni. It is a brand new 94c with very few rides on it, may be two dozen at most. I know there is a thread here just recently where the guy was running his around in the snow and he had this same issue. Not sure what the thread name is or what the end result was.
Anybody know what caused this ??

EDITED by hoser added Comet 94C Duster to the subject notice how much more relevant the "Similar Topics " at the bottom of the page became....

What is your belt width? Sag?
Also what is your belt to sheave clearance at stand still.

We run Dayco HP3004 Length: 44.125” (44-1/8") Width: 1.187” (1-3/16")

I believe the Honda belt is #704148 Length: 43.33” (43 21/64”)OC Width: 1.13” (1 1/8”)
so it is a bit longer so we got some sag.
I tried running and equivalent belt to the Carlisle UA434 Length: 43-15/64" Width: 1-13/64" but this didn't work as it was way to tight.

Belt to sheave clearance at stand still ---- ?? not sure what you mean

Why are the faces so pitted and the edges are banged up

I think Baz was saying Belt guards (( safety ))

Ps

break down over kms traveled = not much

Opps Sorry

break down over kms traveled = +28.5 miles x 2 + a bit

The ratio has dropped so you were up 57 miles but now - Clutch

not good but you will get there

Std OEM belt width is 30.2mm(1.19in)
Service Limit.............27mm(1.06in)
The sheaves are the pulley halves,the inner is the fixed sheave,outer is the moveable sheave.
Did'nt you go to church? Never sing" Bringing in the Sheaves?"

Belt clearance at rest is the clearance between the belt and sheave face-not running.
I would be taking apart the clutch and closing up the sheaves to see what fully closed in dimension is left on the outer edge,simulating full shiftout.
When your putting on the cover,is it all square? Weigh your pucks,see if they're all same weight.

As Adrian says,you have a lot of damage around the sheave edges.
Must be from rocks and crap.
IF theyr'e doing that there,then imagine them going into your clutch cover as well,and jamming it on one side.?
Install a skid plate under to stop crap into sheaves/cover.

Those few pits you see are nothing. I have already filed scratches on the faces and the 102c on mine has some hits as well with a few chunks missing. I put one of the air side scoops on my brothers machine to kind of protect his clutch but the rocks must be coming from underneath. Not sure what I am going to do about all this yet but thanks for the heads up on building shields. Was kind of thinking similar after the first file down of the faces. We ride in some tough terrain at real high speeds, 64.3 mph . I don't think a rock got in there because we were coming down a high speed straight that was not full of rocks, it was mostly hard pack sand. I will look for a rock mark inside the cover when I take it apart. We are planning on running it with just three pucks and not the original six as two are now missing and from what I read on the net you can't get them separate. My brother wants a 102 so we will order one now. In the mean time it's gona run with three pucks.
Thanks for the help sheep masters.

Here's a couple of pics of the road. As you can see it's mostly sand. No real rocks in my opinion.
In the first pic you can see a few small rocks as we are approaching the turn but just a few yards behind that all the way down the straight it's sand.

No real rocks?

Here..... allow me to be a wise ass.... rocks are those small little round things that are laying all over the road! LOL

Those little critters will play havoc on a clutch. All it takes is one the size of a marble to do some damage.

Rand

Next ride out I will try to get some pics of real rocks and post.

We have pretty much the same terrain here as where you ride. There are areas here where I won't go because the Ody doesn't have enough ground clearance to get over the friggin boulders. I remember when I had my 400EX and it had a whole 4 inches of ground clearance. I tore up 2 skid plates riding that damn thing. My buddy has a Polaris 400 Sportsman with plenty of ground clearance and I remember always bitching at him when he would take me on new trails...... Dave, stay out of the rocks.... DAVE STAY OUT OF THE ROCKS!

Rand

Go to Glamis one time, there you will find no rocks, that is what sand is, that stuff on that road, rocks!
I have friends complain when I ride the 500 about getting roosted, I think getting roosted with those would kill Goliath!

Well took the clutch apart. Form your own opinions.
A lot of rust came out of the clutch. Looking down the hole of the outside face I could see a large lip of metal that I die grinder out. Measured .010 clearance between shaft and bushing (don't know if that is bad or good cause I don't know the max number). We were missing 3 pucks not two, but there is 9 pucks in a 94c so I just spaced them evenly. Pucks seem to all have scarf marks on them but they are all the same so I think it is normal wear marks. A lot of this might be due to the fact that we didn't put any lube in the right places, in fact we never lubed this 94c -- a mistake for sure. On a positive note the outside cone shaped puck cover does not have any marks inside so it does not seem like any rocks got in there. When I removed the skid plate seen several rocks ( about 3/4" ) trapped on the skid plate. Also looking at the faces of the clutch I think there is a snow storm of rocks back there. We gona ride what we got for this summer and this winter will make deflector plates.

More

Wow... Sorry for the bad luck. You said it was running like a rocket just before it happened, was that top speed wise? Wonder if the belt rode real high and caused it to toss your pucks? Gonna go with a 94c again?

64.3 mph
Probably not. Possibly 102.

You said that clutch was new? That thing looks hammered! Rocks are definitely hitting that thing quite a bit.

I agree PUT that bash plate on and those faces are trashed and will
speed up belt wear.

Looking at the moveable face the way it is sitting with the spring fitted
is the same as see thread.

viewtopic.php?f=2&t=15180&start=50

once it is together there is not enough tension.

What length is that spring.

What Part No clutch did you get.

My thoughts exactly! Glad you said it Rand. Looks like a lot of fun though! Canada is a gorgeous country.

You need to read the setup Info re a FL350 94c Clutch

6 pucks is standard out of the box
your not missing any pucks

No worries...till next time."Who ya gonna call?"

Interesting that you had a similar issue I have. Ironically enough, I just got off the phone with Don Jackson from Comet about my problem (like this one)

He first thought it was something on one of the slide ramps that made the puck flip. Look for any imperfections that can cause a puck to not slide smoothly. Also suggested using a dry film lubricant on the ramps. (graphite spray or something similar)

He wanted me to open up the clutch and take note of the bearing position (spring rests on the bearing I guess?) when I asked about the outer cover not sitting higher than the boss pin like Wyeeoddy was suggesting.

Asked what color spring I had. Orange just like yours. (came stock with it)

Lastly said the clutch was designed for a 1 3/16" belt width. Mine is 1 1/16", so I need to try a new belt.

Looking at the damage and your terrain, it may have been a rock in your instance. But not in mine 100% We'll get to the bottom of this....

I don't see any signs that clutch was ever lubed viewtopic.php?f=28&t=6719 lube it good before restore returning to service Follow some of the similuar topics at the bottom of that thread plenty of 94C info on this site.

Comet 94C

Your right it was never lubed.
We went for a ride today and just got back.
The clutch works well with the six pucks and clutch lubed up but the carnage continues. Will post pics in a new thread in a bit. Having dinner right now.

Don't know what length spring as it is all together now and I didn't measure it, sorry.
The clutch part no it don't remember but it said it was for the fl350.
Works well with the six pucks but then why are there nine slots for pucks ??