Here's a couple pictures of my Power Bloc clutch cover. Anyone ever replace just the cover? If so, any ideas on where to buy a cover? The clutch was working great before I pulled the motor (( Internal Combustion Engine ? )). The only reason I removed it was to ship the motor (( Internal Combustion Engine ? )) to Hoser. (Thanks again Hoser.) Originally, the only sign of trouble was the head of the bolt being half way recessed. Am I SOL... time for a complete new clutch?

How about some pictures of the end of the shaft on the clutch.

HRD racing can probably sell you a new cap, bolt and washer but if the end of the shaft is bad your better off with a new clutch, BUYER BEWARE of the HRD "better design curve cover" that HRD will try to sell you, if you need a new clutch insist on a ALT cover regardless what he says, also beware he is a great salesman and very convincing he also most likely has a whole shelf of his style clutches he is trying to sell. He is a nice guy and knowledgeable about clutches but IMO his main interest is extracting as much money out of you as he can get.

http://pilotodyssey.com/powerbloc1.htm

Here's the pics. 10-4 on the Alt cover. The link was helpful. thanks.

I repaired Mudbogger's shaft but your damage looks further back into the shaft than his was
http://www.pilotodyssey.com/PO/view ... tch+repair

The only thing I worry about with this repair is the thick washer I make as a spacer to replace the bad shaft I cut off sticking out and tearing up the bushing in the movable face the only thing that locates the spacer I make is the center bolt I kept the hole as tight as I could.

Well, well... HRD Racing is about 10 minutes down the road from my work. I'll see if I can bring my clutch over to Harold next week and get his feedback.

Yeah stop in for sure didnt know you were that close, pick his brain on clutching too the guy has been playing with them for many years, ask about any tricks or tips for your driven heck you might even take your driven with you when you go.

One of these days I will get out to his area and stop in myself.

http://pilotodyssey.com/pilotdriven.htm

Yeah. The end of my shaft doesn't have anything remaining that resembles a notch for a D washer.

Time to start shopping for a deal on a new clutch...

I think ATVR still sells the ALT power bloc

I just ordered a new PowerBloc clutch from ATVR. I spoke with Neil. The only spring they supply with the clutch is 3 3/4". I told him that my Pilot is a ported, no rev limit, CR500. He recommended running 10 washers in the pucks. I told him that my old PB clutch was setup with 11 washers. He said that with 11 washers it might be running slightly below peak performance for my motor (( Internal Combustion Engine ? ))... which should be about 7600 to 7800 rpms. (I hope I'm recalling that number correctly.) I'm just passing this information along... Not purporting it as gospel.

As I mentioned previously... The old clutch was working fairly well. I never did mark it with a sharpie to see how far out it was shifting. (I wish I had.) But, I was able to hit 72MPH consistently with a GPS on a power-line road near my house. Acceleration was great from 0 to 50 but, after that it seemed kinda flat... Like the RPMs were too low to provide a quick upshift above 50 mph. We'll see how the new clutch compares.

BTW -The old spring is only 3 1/2"... I'm assuming that it started out at 3 3/4".

Try it with the settings they suggest.


You could always install your old pucks weights and spring and compare to the weights they suggest.

Your spring could have been a 3 3/4" but they do make a 3 1/2" spring also.

Make sure you have that D washer lined up 100% right before you tighten the bolt, recheck the bolt after each ride for about the first 5 rides to ensure its still tight.

Did you ask them if they had a longer bolt it looks like a few of the threads in your crank had been damaged at one time to your not really using the first 3-5 threads, their is plenty of good threads deeper in the hole if you can reach them.

I asked ATVR if they have a longer bolt. They don't. They suggested that I try to locate one in my area - 12mm x1.25. If I can't find one, they offered to make it for me. I didn't ask how much. I know I'm not going to find the right size bolt at Home Depot or Lowes... Any on-line sources for bolts?

I think I found a source online for a longer bolt. Their 12mm x1.25 hex bolts are "Class 8.8". Is that the correct grade? EDIT - Okay, the bolt that came with my new PB clutch say 8.8 on the head. So, I'm good with that.

Next Question: The bolt that comes with the PB clutch is 140mm in length or 5.5118 inches. I can buy a 160mm bolt which equals 6.2992 inches. Hoser - Do you think that'll be too long? EDIT - I think I found a 150mm bolt. That should be perfect.

Bolts - McFadden Dale Hardware - there is one in Corona and Ontario -

The new PB that I got from HRD did not have the D - Harold said it was not needed with the new design.

I do have an old PB sitting in a box that may have a useable cover. Will look and let you know - I will be in the IE next week.

BC

You have his curve cover and not the ALT cover?

http://pilotodyssey.com/HRD1.htm

Ken - Thanks... I've already got a new PB ALT clutch from ATVR. I was able to get the right bolt thru Fastenal in Victorville.

One thing I noticed is that the new clutch has a thicker inner face. The lip is about 3/16" compared to the old one that practically came to a point. It's got less clearance with the jug than the old clutch. But... it should be okay.

NO NO NO !!!!!!

The inner face has to be put in a lathe and thinned out like your old one to provide clearance on the CR500 cylinder, the 500 cylinder is wider, don't try to bolt it to your Engine if it hits the Engine you can bend the back face.

See where they also ground your cylinder for clearance?

Surprised ATVR didnt tell you this.

Okay... Thanks Hoser. Yeah, I specifically told Neil at ATVR that I was buying the PB Clutch for a CR500 converted Pilot. I've been away from home for a while so, I haven't tried to put it together yet. I'm picking-up the 150mm bolt on Monday. I'll call Neil again and post some pictures then.

Updates?

ATVR milled down the inner-face free of charge. The clutch is working really well. I went with 11 pucks... same as the old clutch. It's definitely pulling harder from 40 to 70mph now.

Nice, you get to the point where you think you need to remove weights then you might consider a new spring at that point, the springs will sag and get weaker with age but its not a huge issue you can remove weight and keep running the old spring..