This is on an 02 Sportsman 500 HO

I have zero experience with belts and clutchs but mine was starting to rattle so I took it apart.
Looks like I need to replace the bushing between the main shaft and the out plate, also between the shatf and the sheave (the outside plate that the belt runs on. The buttons look worn too.
So, I ordered a rebuild kit from royal distributing, it should be on its way now.
The dealer was less than helpful and their prices were crazy.
I made a little puller to get the clutch of the crank, now I'm kinda stuck.

I'm not sure how to actuall dissasemble the thing. I was hoping it would all come off the back of the shaft
once it was off the machine but no luck. There is what look to be a nylon nut possibly threaded onto the shaft with 4 notches
in it. Do I need to thead that off or something? Probably another speacial tool I'll need to make or buy?
I'd like to stay as far away from the local dealer as possible.

Thanks for the help in advance
Corey

 

where are you from??

 

I am in Nova Scotia.

Can anyone answer any of my questions though? [img]i/expressions/face-icon-small-smile.gif[/img]

 

weel you need a holding fixture and a spider tool which you can use to turn the spider off the inner shive to get the outer shive off

 

A holding fixture such as a vise? Maybe I should have just left it on the machine?

Is the spyder the plastic thing with 4 notches in it that I described? It does look like it is threaded onto the main cluth shaft. I tried to give it a few taps with a puch and hammer but no go. I didn't want to work to hard on it since it looks like it is plastic or nylon.
If so, where can I get a spyder tool. I fmy only option is the dealer, what can I expect to pay. My dealer is not very nice.
I took my clutch to them but them wouldn't tell me how to take it apart or answer any of my questions. They would rebuild it but they wouldn't tell me how much. Just the parts alone started to add up to $200 before I gave up.

 

I think royal distributing has clutch toolsor you can do an internet search
the snowmobile clutch tools are the same as the atv tools

except the snowmobile needs one extra tool to remove the spider retaining nut which the
atv doesn't have
you will never loosen it with a punch it is torqued to 200 foot pounds and has green loctite
on it

 

Mine does have a nut.
I called royal but they have no tools listed for atv's other than a puller.
They do list a bunch for sleds but there are several variations and I don't know which one(s) I need.

I think I will just make my own. I think I need one to remove the plastic jamb nut and 1 to remove the spider itself.
Does the spider normally need any heat to get it moving? 200 foot pounds and lock tight sounds like it might be a tough go[img]i/expressions/face-icon-small-smile.gif[/img]

Also, if anyone has the proper tourqe setting for putting this stuff all back together that would be great.
Specifally I am looking for the main bolt that holds the clutch to the crank, the outside 3 cover bolts and the spider(200 lbs?) and jamb nut.

 

http://www.hotseatperformance.com/ps...ctGroup_ID=605 should get you what you need. As a side note you may want to make sure that your off set is correct along with center to center distance. These measurements can change as your engine mounts wear.

 

well I use the standard polaris snowmobile clutch tools to work on my sled clutches and atv clutches!!

 

Possibly a another stupid question but does the spyder turn off clockwise or counter-clockwise