I just received the infamous "black spring" from EPI and am ready to install, however, I have hit a snag. I have read what everyone says about driven pulley removal, and had no problems getting the retaining bolt removed, and from what I have read, it should just pull right off, but there is something else holding it on, and I haven't read anyone mention it. It is just as tight on the shaft as before the retaining bolt was removed. any suggestions or is there something that I missed?

 

tell you what go to http://atv.dnsalias.com and click on tech tips should help if not hollar back.just my 2cents hope it helps.

 

I dont know,mine pulled right off. Are you sure your doing the right pullie? Its the rear one that you want to take off.

Andy G

 

Thanks for the replies folks.

Yep, I am taking the right one off, it is the rear driven pulley (the thin on) I looked at it, looks like there is another type of nut that is around the shaft just inside the hole. I am puzzled since I have visited nyroc's tip website and saw no mention of it. I even looked at the parts manual on the website and saw no mention of another retainer, but the pulley sure isn't just sliding off, that is for sure! I don't know if I can get to the other retainer or not, I might have to take it in (perish the thought).

By the way, just to let you folks know, I used a wooden dowel rod (about 3/4" thick) to brace between the floorboard and the driven pulley, I didn't like the thought of metal-to-metal contact. This worked like a charm.

Anyway, if anyone has seen this before, please let me know what the heck is going on. Thank a million!

 

It is rusted on. Another guy had to very carefully pry around and around being extra careful not to bend.

Patience will pay off. Stay calm and try to pry it in a way that won't damage it. By a bar, heat and bend a screwdriver. Cautious thinking may be needed here. Two prybars (one opposite the other ) is better than one. I don't believe heat is the answer here, since there are seals you don't want to mess with.

Make sure you have greased it well so it won't rust again.

If it is not rusted, maybe the clearances are a tad small and it has a slight interference fit. If so, you still have to gently pry.

I don't know if you think you could devise some kind of puller. I don't remember seeing any room for that.

 

If it's rusted on and there is no sign of grease around the clutch buttons, it may have been dry from the factory. We had a number of secondary clutches replaced under warranty due to lack of grease.

 

The first time I did the belt deflection adjustment, getting those little clutch buttons out was a bitch! Patience was all gone by the time I got #4 out, but I greased them up real good putting them back in and they should be easier next time. I had the best luck with a very little straight blade screwdriver. I just got the black spring yesterday, going to get it on this afternoon, going to look into a snorkle mod also!

 

ConMan,

I am the guy NYROC is refering to. My driven clutch was just about welded onto the driven shaft with Rust!!! See my post today. I used the largest Craftsman screwdriver that I could find and very carefully applied preassure to the back of the pulley an inch at a time while rotating it by hand. It took almost 2.5 hours to get it loose!! Finally, while I had both feet braced against the machine, pulling for all I was worth with my hands, it popped off. I went flying across the garage floor.(I did not drop the part though !!) I used fine steel wool to remove the rust and greased the area well before assembly. I can email pic's of this to anyone who is interested.

ED

 

I want to see the one that you are flying across the floor.[img]i/expressions/face-icon-small-smile.gif[/img]

 

Unfortunately,

I was too busy swearing to take a photo at that point.

Ed[img]i/expressions/face-icon-small-disgusted.gif[/img]