I am in the process of removing the drive & driven clutches on my 1991 Trailboss. I am at a stand still now as I need some sort of special puller tool to get the drive clutch assy off. Do I need to order it from the dealer? I would rather make up my own. Can anyone help me out here? Has anyone made up their own puller? Anyone know what size the threads are inside there? What does this puller look like?

Any help appreciated.

Keith

 

Check out www.hpd-inc.com for your info. The secondary will come off without special tools.

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Jerry Goodman '99 400L, '98 TBlazer

 

The puller for your primary clutch is the same as the one they use on their sleds .
It has a hex head with threads just below the hex and a long shaft about 8 or 9 inches long that bottoms out against the crank when you tighten it up. (no perverted
comments please)..... To remove the clutch you have to tighten the puller quite
tight then give it a couple of smucks with a
hammer to break the taper free. You could do it the old fashioned way if you're careful
without a pullel Loosen your clutch bolt off about 1/2 a turn from seated then give it a
couple of good smucks with a hammer and a block of wood. This should pop the clutch off if youre careful. Its always worked for me in a pinch. By the way , use a good block of hardwood cause softwood will just fly all to hell .

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Thx for the input. Now I have seen the tool at H.P.D I have an idea. What if I push a piece of round steel rod deep against the crank, then get a bolt the right size and thread it in. The bolt will eventually bottom out on the rod and pull the clutch assy off the tapered shaft. I appreciate your help.

Now...anyone know the thread size and pitch inside the clutch assy? I can measure it tomorrow I suppose.

Keith

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1991 Polaris Trail Boss, 1983 XR350R, 1983 XR100, 1996 Sport 400