I bought a new clutch kit and the directions suck. Can anyone help? I cannot get the secondary pulley off to put the secondary spring in. Also the primary won't engage. I really don't want to spend $25 for the clutch tuning manual. It is an AAEN clutch on a 2002 Scrambler 500 4x4.

 

Not sure how the secondary clutch works on polaris, but the kawasaki's are right hand thred ( left to tighten and right to loosen). It was also tourqed to a million friggen foot pounds!!! Try going the other way. Or when all else fails, swear at it. seems to help [img]i/expressions/face-icon-small-tongue.gif[/img]

 

The secondary on Polaris's are just pressed on, should come off pretty easy when pulled, but sometimes they don't. Just don't beat it with a hammer or anything.

 

Boneshock what kawi do you have?

 

I can't get the secondary pulley off to even get to the secondary spring

 

Not mine. I have a KFX 400. I was putting the black sping in my dads p650. I thought the black spring was hard enough, but the red spring was a real pain in the poop shoot.

 

You may need to get a puller from a dealer to get the pulley off.After you get it off take the snap ring off and it will come apart.

 

I have used the gear puller but I don't want to use a breaker bar because I dont think it should require that much torque. Also someone told me that in order for the clutch to engage with an aggressive clutch kit, the engine needs to be running at about 4500 rpm. I was just want to know if that was true or not.

 

I have never seen a scondary clutch that would not come off with just a quick tug, Seems odd to me try giving it a hit with a rubber malet on the sides just to jar it and then grab with both hands and tug , I know this sounds stupid but did you remove the bolt.

 

Yes, I removed the bolt and I tugged so hard on the thing I was moving it sideways. I still couldnt get it out with a gear puller.