It's been a while since I've had to delve into the ATV brain trust for answers on my Polaris... but the time is nigh.

I have a 2001 Polaris Trailblazer 250. A while back it ate it's oil pump, and while it still ran afterwards (Using a pre-mix) it was a right pain in the neck to get it started, and the pull rope didn't feel like I had much compression left. So it's time for rings.

But before I can do that, I of course have to get the engine out. And before I can get the engine out, I need to get the whatever-its-called off the engine that changes the speed. The thing the belt goes on, one half of the transmission.

I've tried a 3-jaw puller, but I've gotten it so tight that I worry about breaking the expensive-looking belt drive part, then I'll really be in trouble. I wasted money on a manual, which simply said "Remove the PTV", and doesn't give specifics. (A side note - what is up with repair manuals the past few years? After doing some work of the head-gasket change variety on an Isuzu Trooper, I've decided I could write a better manual than the one I had)

So, can someone chime in and tell me what horribly embarrassing and silly thing I'm forgetting when trying to remove the drive pulley from my engine? Do I need to stop being a sissy and just put the 3-jaw puller back on and make use of my biggest breaker bar?

 

polaris has a special puller for the clutch, u take the center bolt out and put in there puller and use an impact and basically push it off the end of the crank

 

I believe the bolt size for the puller is a 7/8" fine thread, I have one that is for a puller I made in school years ago, it was just a grade 8 bolt about 6" long that we cut the threads deeper on. I use that bolt and a 1/2" pin about 2.5" long to press against and it pops the clutch off easy.

 

a 7/8" fine thread bolt 6 inches long, and a 1/2" diameter pin 2 1/2 inches long?

You put the pin in the bolt hole down the center, and use the bolt to push against the pin to get the pulley off? I guess I'm not picturing it right.

I was worried there was a special tool, but I haven't got time or money to be searching for Polaris tool number #3.141592653591 or whatever it is, I hate when manufacturers make something that requires their tool to take it apart.

 

polaris does have a special tool for it, this was just something I had laying around here, I used to use a 7/16 chinese socket to push against with the bolt, but it split it out, so I cut this piece of shaft the same length as the socket. I'm not 100% sure on the bolt size without going out and looking at it, but I think it's 7/8.

 

The thread size is 3/4 - 16.

 

Ebay has the tool for like 30.00 better than messin up the crank

 

You don't have to remove the engine just to put in rings. Also you don't need to just replace the rings. That is asking for trouble. Bore the cylinder and replace both piston and rings.

 

You need a tool called a Drive Clutch Puller. Polaris makes them as well as aftermarket places like EPI. EPI part number is PCP-1 and is 35.00 You pull the center bolt out, thread the clutch puller in and tighten and the clutch will come off. To reinstall the clutch you push the clutch on the shaft and then torque center clutch bolt to 47-50 ft/lbs.

EPI site is www.epiperformance.com and search for the part number PCP-1.