OK.......How do you get the drive clutch off of a 250 trail boss? I'm new to Polaris atv's and have a tranny problem but this drive clutch doesn't want to cooperate. Do you have to have a special tool for removal or does someone know another way?

 

There is a puller for it. It threads into the clutch and there is a piece on the end that pushes on the crank. If you find a bolt or some threaded rod that will thread into the clutch and a bolt smaller than the inside of the clutch you could also use that.

 

the Polaris dealer here just let me borrow their puller

 

so i need to find a bolt small enough to go thru the clutch to rest in the end of the crankshaft to protect the crank. The inside of the clutch is threaded? (I didn't notice, of course it was getting dark) All I have to do is get a bolt to match the clutch thread size and push against the bolt I use to protect the crank and it should come off. (?)

I don't have a Polaris dealer anywhere close to borrow from so I'll improvise

 

I drilled and tapped the large bolt so the smaller bolt would thread into it. This keeps it from getting crooked when tightening the large bolt. It is very tight. Impact gun helps. p-oil. bfh also helps after impact stops tightening.

The small bolt should be hard to prevent bending. (yes it is that tight.) The large bolt should not be hard if you are going to drill and tap for the smaller bolt.

Grease the threads before threading into the clutch.

Good luck.

Did I tell you it is tight..

 

as many times as i have had to take the clutch off i should just buy a puller

 

Anybody know a good place to buy/order a puller? I'll just buy one!

 

check ebay

 

What I've also done is found a bolt that will thread into the clutch, tipped the bike on it's side and poured water in the center of the clutch. Put the bolt in and push outside (winter of course) and wait for the water to freeze, expand and push the clutch off with no effort at all. Gives you some time for a bevvy and a break. Cheapest puller out there but very dependant on the weather [img]i/expressions/face-icon-small-smile.gif[/img]

 

Best bet is ebay or Dennis Kirk for a puller.If you plan on owning a Polaris it is amust for a lot of repairs.