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Need help 2000 Millenium Mach.

1K views 14 replies 4 participants last post by  MrMACHZ75 
#1 ·
Ok. I completely rebuilt this thing top to bottom over summer. Of course wasn't till the snow flew that all the bugs came out. Pretty much straightened everything out but when my water pump went (plastic impeller stripped) I haven't been able for the life of me to get the clutches to line up. I had them perfect when I first put the motor together and put them back in then the water pump stripped it never overheated but got hot had to pull motor again to fix pump. Now I can't get it aligned. I'm ready to blow my brains out. I have the tool from royal and have used a steel rule to measure x y z. I thought I finally had it. Nope. Belts tighter then **** squeals like crazy I don't think it's secondary adjustment because the ribs sit flush with the top of the secondary. Alignment must be out.

Both clutches I just completely rebuilt cleaned and replaced all springs buttons hardware everything inside.

On another note,... I never had to flush oil pump before worked great before water pump now I only went up and down street realized clutches wrong came straight back sled never even warmed up but I don't think oil pump working right.

1. There was an odd smell I've never smelt before and 2 it hardly smoked when usually it smokes bad which is how I like it. Plugs are perfect so no speeches about how I pumping too much oil pls.

Thanks for any advice.
 
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#2 ·
The steel ruler to get the X Y Z is the best method in my opinion. I use ratchet tie-downs to secure the motor in all 4 directions and it is much easier to place it perfectly straight one click at a time. The X Y Z measurement I used on my Mach was: X=35.5mm Y=36.5mm Z=120mm. It sounds like it would be a good idea to check that first. After you are 100% sure to have this right, I would adjust belt deflection because where the belt rides over the secondary is not a precise indication of belt deflection. Use a good quality fish scale and push down on the belt until it reads 25,5 lbs and hold it there, the deflection should read 38mm. Adjust the secondary until you get 38mm, it takes long sometimes but after you are set up you should be good for a while.
 
#5 ·
I have a 98 motor in a 2000. With 2000 RER secondary and primary,...

Also. After checking my numbers I'm still confident I'm close.

I think I messed up on my secondary. I took the 3 10mm bolts out and removed the adjustment wheel ,..

Now question,... there's 6 threaded holes. 3 are for the wheel the other 3 beside are for opening the sheaves right. I think I put the 10mm bolts on the wrong holes. Plus I had it at notch 5 not 2. Does this matter
 
#6 ·
Also one more question,... I used that exact diagram for my measurements. X is around 36mm Y is at 39.5 and th distance between clutch du faces 120,...121,......: this 121. Is it distance between faces in the angle the belt runs on or longitudal to each other looking down at them?
 
#8 ·
Ok, looks close enough for the X and Z measurement. The only one that is suspect to me is the y measure because it tells you how much the motor is tilted sideways to resist the engine torque. The 39.5 in my opinion is too much tilt and might pry the belt too much sideways.
 
#9 ·
Also one more question,... I used that exact diagram for my measurements. X is around 36mm Y is at 39.5 and th distance between clutch du faces 120,...121,......: this 121. Is it distance between faces in the angle the belt runs on or longitudal to each other looking down at them?
Here's the deal.

The 98 CK3's use a longer belt (069 last three digits) and a formula secondary clutch. Distance between sheeves is 123 mm
99 to 03 CK3 use the 066 belt which is about 1/4" shorter.
99 to 03 with formula secondary the distance should be 120 mm
99 to 03 with RER secondary distance should be 121 mm
 
#12 ·
Ok I get that but you didn't read above. I have a 98 motor in a 2000 sled with an RER secondary from the same 2000
Motor doesn't matter, the primary clutches are the same through the years but there were two different secondary clutches.

If I were you, I would set the clutch per the 121 mm distance because you are using the RER secondary with X and Y as indicated in the drawing. The 069 belt is a one year only belt (98)and your choices for aftermarket belts are really limited.

You're only other option would be to set the distance @ 124mm due to you using the 069 belt and RER secondary.

Take your time setting the clutches, you're looking for 37.5 mm at the front and 36mm at the rear and choose the distance as I mentioned above depending on what belt you choose to use.
 
#14 ·
3 are used to retain the ring which is chamfered to adjust your deflection.
There is another with an arrow pointing a it, this one is used to spread the sheaves to replace the belt.
I believe the other two are covered by the deflection setting screws and associated shaped washers.
 
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