my 01 is getting a clutch kit in it i bought the pullers got the first clutch off now the secondary wont come off .... the threads wont touch each other because it seems that the puller is like a 1/8in too long....now i now just say cut it but is there a bushing that needs to be removed like the primary clutch had inside????

 

If it helps any,I just use penetrant spray inside rear clutch,HEAT inside clutch against transmission splines with heat gun or torch,and use a small socket and air chisel with a dull bit (to set inside socket and not damage shaft), impact while someone else pulls on clutch! Usually comes off fairly easy! Only have had to do this on the ones that wont come off with standard puller. There is no bushing in rear clutch like in the front! SURE you have the right puller(several for different clutches) IF positive then can try to grind down or cut flat to allow engagement to threads,then can impact off.

 

the secondary should just slide off..just has splines instead of a cone shape like the drive clutch.

 

They SHOULD,but I've encountered a lot from the mud buggers, lot of water riders, and some that have been on forever,etc that can cause the rear clutch to do basically the same thing some rear drive shafts can do rust up and freeze up on the shaft OPT

 

Yes, old polaris tech is right on the money, a touch of 200 degree heat, a dab of penetrate oil, and off she comes!!

 

I am in the same boat. Secondary clutch on a 2000 Scrambler will not budge. I have soaked it for 4 days and followed instructions in the DIY clutch puller thread. Still no luck. Cannot find a bolt that will thread into the secondary clutch.

Is the heat prescribed here in conjunction with a puller?

What puller is the right one to buy? I don't want to keep buying $20 pullers until I have the right one.

 

Take a rubber mallet and a small piece of Wood and tap on the Helix all the way around it

 

Try this guys way,he's doing it on a axle but should work on the clutch. Should release before ATV lifts off the ground,i'd hope.

YouTube - Polaris Sportsman CV axle removal (Redneck Version)

 

I would try some penetrating oil on it and let it soak if needed. If still cant get it EPI makes a secondary clutch puller that fits all atv models 85-09 part # SCP-1 for $24.95.