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08-09 QRS Secondary Clutch Tool Directions 

The easiest method is to remove the jackshaft from the sled.

• Remove drive belt, the black adjuster from the end of the jack shaft.

• Remove the bolt from the top gear in the chaincase.

• Remove the bearing keeper flange from behind the secondary clutch.

• Remove the jackshaft from sled. ********You may need to heat the bearing keeper bracket with a heat gun.

Once the jackshaft is removed, install the spring compressor into the jackshaft and snug the tool by hand.

NOTE: We have found that some threads in the jackshaft can be a little hard to start the QRS Tool into. Thread in by hand at first and if the tool does not want to go into the jackshaft very far, use a 7/16 wrench or adjustable on the end of the acme rod to thread the tool in at least half way.

You will now heat the 4 torx bolts on the backside of the secondary clutch, and remove them. These 4 bolts thread into the back of the helix, holding it and the secondary spring in. Do Not Attempt To Remove The Helix and Spring Unless You Are Using The QRS Tool That Came With These Directions.

Once the 4 bolts have been removed, back off the spring compressor. The helix and spring will come out of the secondary as you loosen the compressor. Remove stock spring and helix. Re-install in reverse order.

NOTE: If installing the Cudney helix, position it so that the CR is where it goes into the secondary on the roller. Replace the jack shaft, gear, bolt, bearing keeper and black adjuster. Install the belt. Set the belt deflection so it is fairly tight and lock the adjuster.
 
A Quick Change Belt tool is also available for the XP Sleds. It can be carried in your tool kit and makes changing your belt VERY easy!

If you have any questions or problems, don’t hesitate to call. Click here to print the PDF instructions.

Thank you,

Chris