Kawasaki Discussions about Kawasaki ATVs.

Need Help with Drive Pulley Disassembly.....

Thread Tools
 
Search this Thread
 
Old Jul 24, 2003 | 07:13 PM
  #1  
brewster2003's Avatar
Thread Starter
|
Pro Rider
Joined: Jun 2003
Posts: 204
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

I am replacing the movable sheave in my Drive Pulley and do not have a "Drive Pulley Holder" or a "Drive Pulley Wrench". The object of what I am having difficulty with is seperating the "Fixed Sheave" from the "Movable Sheave".

I am sure one of you guys has done this with out the recommended tools. Let me know how you did it ......I don't want to tear off any of those fan blades on the fixed sheave.

Thanks a bunch :-)
 
Reply
Old Jul 24, 2003 | 07:16 PM
  #2  
nyroc's Avatar
Pro Rider
Joined: Oct 2001
Posts: 2,776
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

A guy named nyroc has compiled some tips in his website on how to do that. It has pictures too. Here is the link.
 
Reply
Old Jul 24, 2003 | 07:24 PM
  #3  
brewster2003's Avatar
Thread Starter
|
Pro Rider
Joined: Jun 2003
Posts: 204
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Hi Nyroc, trust me your site has been a wealth of knowlege and I thank you much for it, but I am not seeing how to what I am talking about there. I am talking about the two items that sandwiches the spider in the drive Pulley not the Driven Pulley.
 
Reply
Old Jul 24, 2003 | 07:33 PM
  #4  
nyroc's Avatar
Pro Rider
Joined: Oct 2001
Posts: 2,776
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

my bad, did you look at the article that djnemesis wrote? here, it speels the whole procedure out in such fine detail that some people don't bother reading down far enough to see the good stuff. And the other one, here that someone that I forgot sent me the photos of.

You dont need the pulley puller, and you don't need to fabricate anything else or buy those special tools.

It appears that you take the bolt out but don't need to remove the fixed sheave.
 
Reply
Old Jul 24, 2003 | 07:50 PM
  #5  
MDG's Avatar
MDG
Range Rover
Joined: Jun 2002
Posts: 187
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Can you replace the wear shoes without pulling the clutch off?

Thanks
 
Reply
Old Jul 24, 2003 | 08:55 PM
  #6  
brewster2003's Avatar
Thread Starter
|
Pro Rider
Joined: Jun 2003
Posts: 204
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Nyroc,

Maybe I have worded something wrong. I understand how to change the spring and weights and all that. What I need to do is separate the two polished curved plates that the belt fits in, behind the clutch spider.

If we are going from back to front the parts would be as such:

Fixed Sheave- Movable Sheave-Spider-Primary Spring-Clutch Cover Plate.
 
Reply
Old Jul 24, 2003 | 11:06 PM
  #7  
alltoys's Avatar
Pro Rider
Joined: Oct 2001
Posts: 1,435
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Brewster,
You can try this. Take 2 1/2 inch bolts about 3/4 inch long grind off 2 sides of the head so they will secure better into the jaws of a 6 inch vice. Bolts standing straight up install the vane part of the sheave onto the bolts make sure the face plate is removed and the spring. Bring up the spider past the end shaft so the spider is higher than the sheave. I then use a what is called a cat bar a long 3 foot bar that has a slight bend in it with one end flattened and the other pointed this allows for the bar to go around the centre shaft and still fit into the other side of the spider. The bar will rest on 2 sides of the spixer you then have to turn clockwise to break it loose and beleive me it is on very tight. Do not use a hammer on the bar you may break off one of the arms on the spider. When it breaks loose it will turn off anticlockwise you can then get to both halves of the sheaves. I thought I was going to break my spider because it is on very tight but it will loosen.
Is this what you are talking about.
 
Reply
Old Jul 24, 2003 | 11:30 PM
  #8  
brewster2003's Avatar
Thread Starter
|
Pro Rider
Joined: Jun 2003
Posts: 204
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

yes alltoys you are correct.

Can you elaborate on what you mean by the "vane" part of the sheave? Thanks alot.
 
Reply
Old Jul 24, 2003 | 11:37 PM
  #9  
nyroc's Avatar
Pro Rider
Joined: Oct 2001
Posts: 2,776
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Sorry again brewster, I did not pay full attention. I had to look in my repair manual to get it straight. The vane alltoys refered too is the fan/backside of the fixed sheave. You might have to take the whole pulley off for this.

Do what alltoys said, unless you would rather get that drive pulley wrench.

The spider screws onto the fixed sheave with a left hand thread. Alltoys' bolt idea creates a fixture to hold the fixed sheave still. Then the bar loosens the spider.

After you get the spider off you can dissasemble the spider and weights to get the moveable sheave off.
 
Reply
Old Jul 24, 2003 | 11:59 PM
  #10  
brewster2003's Avatar
Thread Starter
|
Pro Rider
Joined: Jun 2003
Posts: 204
Likes: 0
Default Need Help with Drive Pulley Disassembly.....

Nyroc and alltoys,

So if I am understanding you guys right, I am to set the fan blades down onto the 2 bolts sticking out of the vise to create a fixed point of leverage.....correct? If so what the heck keeps one of the blades from bending or breaking?
 
Reply



All times are GMT -5. The time now is 02:59 PM.