Secondary Clutch Help!!

[creed50158]

I have been trying to remove the secondary clutch on my wifes 96 polaris xlt touring sled. I have used PC Blaster and a gear puller and stil can't get it to move, what else can I try? any suggestions would be greatly appreciated!!!!

 

[switchbackfst]

does that style have a snap ring behind the washer?

 

[creed50158]

I don't think so but I will double check.

 

[creed50158]

no it does not.

 

[Dobir]

You need to get a second guy involved...get a pry bar behind it with strong steady pressure and whack the helix with a rubber mallot..its rusted in place...that may break it free

 

[creed50158]

so I dont need a special puller ?? right now I have the sled on its side soaking in PB blaster hoping to break it free.

 

[Dobir]

you do not need a special puller...what it needs is a shock to break the rust..(in my opinion) but make sure it is a rubber mallet...it needs a good whack combined with real pressure from a crow bar..it is almost impossible by yourself..to do both...I am pretty sure its a rust problem...

 

[creed50158]

Thanks alot for all the imput, will do. The snow is coming down here right now. YESSSS!!!!

 

[Scotty]

Sounds like the pulley has bound it self to the jackshaft (corrossion). I had an older ZR that I unfortunately experienced the same problem. Tried everythig to sepparate the driven from the shaft. Even heat from an acetalene torch.. no go.

I ended up removing the secondary and the jack shaft in one piece and pressing them appart in a hydrolic press at my dads shop. Worked fine once all was apart It's a pain to do but better then bending chit with a pry bar and still not busting them loose, or pounding things with a hammer.

In the future... remove your primary and secondary clutches at least once a year and lube with oem recommended antibinding agents like Coppercoat?? Can't remember the product names but do your research... saves the hasstle later.

 

[creed50158]

I appreciate all the info. I have been letting it sit on its side soaking in PB Blaster and will try pulling it one more time. if no go I will take the whole thing apart. I dont want to heat it up cause that will weaking the shaft.