Clutch Issue

[outlander86]

I took my 09 outlander 800 in for its first 10 hour service, and went for a ride after I got it back. It ran fine all day, but at the end of the day, when I was taking it off the trailer to wash it, It was engaging in an odd manner. it would idle normal at like 1250 rpm, and as soon as i put it in gear, it would engage the secondary and the quad idles at like 10km/h... In reverse or hi.. when I press the brake, the machine fights it and then it stalls out.

I assumed there was something stuck in the primary to cause it to stay engaged.. I took it apart, and found that the seal around the clutch housing was half missing! About ten inches of seal were in the grooves and there was no other seal debris to be found! I unbolted the primary and secondary, and as I was pulling the primary, a little piece metal (round about 3mm diameter by 5mm length) flew out attached to a small spring(about 2cm by 3mm diameter) that was badly bent and deformed. I found the hole where these pieces would come from on the primary spindle (where the clutch rotates on.)

The dealer was the last one to work on this system, does it sound like something they effed up?

Any input would be appreciated.

[MoAb Racing]

If they where the last to install the clutch cover then YES. If you where then no. What happened is lots of mud a grime got inside you clutchs and sounds like it jammed the spring cup inside the outter half of the clutch. That is why at a idle it would move because it was still some what engaged....it was probly a little bit stiffer to put in gear then normal also. Now for that little metal piece and the spring, that is the inner part of the "one way clutch" there should be two of them, dont lose them. That part cant fall off the dealer shouldnt have took that off. You have to rotate the sleave to get it too come off, at 100hr service they will take it off, inspect the bearings and reapply isoflex grease.