I am trying to remove the primary clutch from a 1993 2x4 250 Two stroke. I bought the puller but no matter how much pressure I apply it won't come off. Can I put some heat on it without damaging the clutch or does anyone have any other ideas.

 

The clutch is just simply a tapered fit to the shaft, but is definitely stuck. I use a wooden handle to hold the clutch. If you have an impct gun then lube the threads up good and hammer it for just a second or so. If that wont pop it off then you will have to resort to a large hammer and strike it a couple of times. Dont try to break anything, but just use a good solid blow. Aluminum and heat dont get along well, and you have bushings that will get affected by heat. If it comes down to it and there seems to be no way it will come off then you will have to do what it takes without damaging the motor and go from there. Good luck!

 

I've used heat before to get them off of Polaris sleds. You will do more damage by hitting it with a hammer!! Just use a small propane torch, like for plumming, and work it off with an impact, back and forth. Don't ket it too hot or you will melt the seal behind it. We took many off this way and never had a problem.. [img]i/expressions/face-icon-small-happy.gif[/img]

 

I agree with Bubba.Run the puller in until it stops then smack the puller with a hammer.Thighten a little more and repeat until it pops off.

 

also doesn;t hurt to leave the puller on over night. and maybe hit the back side with a little penatrating oil. I tried for two days to get my fly wheel off and couldn't get it. wont out of town leaving the puller hooked up and when I came back about a day and a half latter it had finally popped off.

 

Just to let you guys know I used your method Bubba and it worked fine. Next I will pull the engine and replace all the motor mounts. Then it just needs a chain and sproket set and swing arm bearing and I'll be all set.
Thanks for everyone's help and I am sure this won't be the last post on repairing the quad[img]i/expressions/face-icon-small-smile.gif[/img]