Got my standard clutch removed today, was a bit of a struggle getting the OEM clutch off until I made up a tool out of some angle I had lying around.



Attempted to fit the powerbloc but hit some problems



I was going to have the inner part of the powerbloc machined on a lathe but I think I will grind 1-2mm off the bolt it's hitting as I don't want to risk causing an imbalance in the clutch.

Has anyone had this issue before?

Thanks

David

Hi Dave,I don't know where or but I have seen it written to check the clearance to those bolts.

I would grind the heads also.

hoser turned the back of my clutch down for me worked great on my pilot.

File the head of the bolt down about half way and it will clear the back of the clutch. Somewhere in the powerbloc installation guide it explains the clutch hits that bolt on some Pilots and suggests filing the bolt head down

I'd replace the bolt with a button-head allen bolt. You'd keep all the strength that way.

Hey David
grind the bolt down to about half way and it will fit perfect.....

Thanks for all the replies guys, ill file the head down and get it fitted today. The clutch came with 45 weight discs and I can get 15per puck. Should I run it with all the weights or should I run 12 per puck. I have read on some topics run it with as much weight as possible but also read that it works great with 12.

Let me know what your running.

Thanks

I run 12 and agree it is perfect for my riding terrain and style.

12 will be good if you run 10 or less you need to get a no rev CDI (Capacitor Discharge Ignition) box

Ground the bolt down as far as I'd dare - more than half way and the clutch is still catching, not by much but enough to be a problem.

Going to take it into work and have it setup on a lathe to remove 1mm of material.

Hopefully it wont catch once it's machined.

I'll start off with 12 discs then and see if it suits me then I can always add or remove weight if needed.

Thanks

David

Have you found the post on how to number the sliders and clutch so when you make adjustments the sliders go back in the same slots? Good read if you haven't found it yet.

Yeah I have all my weight blocks numbered like you said, I came across that topic when I was searching for information on the number of discs people fit into the weight pucks.

Thanks

David

Davo,be VERY careful on HOW much TORQUE you put onto the white plastic weight discs retainer/cover.
From Mem they are only about 10-12lbs? A MILD twist!
If you torque more than that,then you have a chance of it breaking free-like Queen's Freddy and setting up a vibrating machine that most women would DIE FOR!

HAHA thanks for the advice bugeye, ill make sure to go easy on them :)

Got my powerbloc back from the machine shop today



Ill hopefully get it fitted at some point during the weekend.

David

YOU can WAIT till the weekend?

IF it still scrapes a bit,you can wrap some emery cloth around a sanding block,and CAREFULLY,sand some more away from the PB while it's all turning at idle speed.
That's what I did on the ex Neil's ATV Racing LT500 Pilot's PB.

I would have fitted it tommorow but there wont be anyone home to hold my wrench to stop the powerbloc :(

HAHA Your brave sticking your hand in there when its spinning, im pretty sure it will be clear this time (fingers crossed) :)

Thanks

David

Bunch of reading here http://www.pilotodyssey.com/PO/viewtopic.php?f=28&t=5777

Only lightly snug the white plastic thing that holds the washers you over tighten you will destroy it trying to remove in the future they will NOT FALL OUT if you just lightly snug it.

You have the keyed cover on your new clutch cant see in the pics you have post so far of your clutch, if you do triple check to ensure the key is lined up BEFORE you torque the bolt you have to be 100% sure and it has to be 100% right if you don't get it perfect you will destroy the clutch.

Powerbloc now fitted

Cant wait to get out and try it

Davo,make sure you mark your bolt/washer/clutch cover with a marker pen to warn of slippage/dis-engagement.
RE-TORQUE your bolt after a few short blatt-braking stints....Have fun.

Also mark your sheave faces to show belt run-out.

Thanks for the advice bugeye, ill make sure to do that before my next trip