I need to replace what is called the 1/2 inch and 1 inch moveable sheaves (bushings) in the driven clutch of a 1996 Scrambler 400. Is this something I can do myself or does this require a special tool? I think I read when there is mostly brass showing they need replaced, its all brass now. Thanks

 

i dont think any special tools are required, just a buddy to help you and some snap ring pliers. after that it all comes apart fairly easy. while your in there you should probably replace your helix buttons.

it might just be easier to find a used secondary clutch on ebay. i have seen quite a few on there lately.

X

 

Actually the bushings are press fit. You may be able to tap them out with a socket and a hammer. Pay close attention to how far each bushing is set into the sheave!! Then to re-assemble put the bushings into the freezer over night and keep the sheaves in a warm place over night. They might drop in place but you may have to lightly tap them into place, again make sure they are in the right place when your done. This is an "old timers trick", that does work most of the time. ** Some installations recommend using Medium Loctite to help hold them in place** I will check my repair manual for mine tomorrow afternoon, if you'd like??

 

no special tools needed. just make sure to preload the spring the same way it came apart.