Does anybody know what size the threads are on the drive clutch for a 2000 scrambler 500. I need to remove the front clutch, but don't feel like paying $20 for a tool that is nothing more than a long bolt. Has anyone done this? If so, please advise!

 

The threads are 3/4 inch, fine thread pitch. You will need to look for a bolt with longer than standard threads, or thread it deeper than usual, as on any regular bolt I have seen, it would be iffy whether or not the threads would bottom out before the bolt hit the crankshaft. I chunk of ready-rod with a nut spot welded to it would work if you could find one in fine thread. It might be tight on the shaft, so don't be surprised if you have to rap the end of the bolt with a hammer a few times to help bust it loose.
Good luck.

 

If you try the threaded rod, there is one more thing to do. Take the last3 threads off the end that will hit the shaft. Just grind them off. I've learned the hard way, that if the part is really stuck, when you tighten the rod down and tap it, the thread on the end will become deformed. Then when you do get the part off and back the puller out, it destroys the female threads.

Good luck
Gary

 

Thanks for the advice. I'll stop at the hardware store on the way home and pick one up. You said it is 3/4" fine thread. But, about how long of a bolt will I need? I have never had it off, but it is only a 2000. So, I'm thinking I shouldn't have to beat it up too much to get the clutch off, right?

 

Lance,

Personally I would spend the $20 on the proper tool. It is harder material than threaded rod.

The inside of the clutch and the outside of the crankshaft are tapered. The clutch can be on there pretty tight.

As mentioned, if the end of the threaded rod gets worked too much it will deform and destroy the alloy threads in the clutch as you remove the rod.

The tool is way cheaper than any problems you could create using the threaded rod.

DJ

 

Take my advise and buy the correct tool. It comes with a lever bar that fits through a hole drilled in the top nut . If the clutch is tight you must only hit the lever bar. If the center is struck it may cause severe damage to the crankcase seal and bearing so to save a few bucks you may damage the motor costing thousands.
Hope this helps your decision.
Matt
2000 500 Scrambler.

 

You've convinced me. I'll cough up $20 to save thousands any day!

 

Good choice .Remember turn it as hard as you can by hand, I have the same machine as you and I didnt have to hit it to get it off , but if you do make sure you hit the lever bar and not the center puller have fun.
later
Matt
2000 500 Scrambler

 

i bought one of those tools from my trusty dealer and the stupid thing wouldnt fit! the threads were a little bit too big, diameter wise. so i had to use a thread file and grind them down. what a pain in the a$$. but it works ok now

 

I pulled the clutch off a SP500 over the weekend and I used a 70 cent bolt(3/4 fine thread?) with a short 3/8 extention as a spacer. I have done this on a few times on sleds as well and have never had a problem yet. One tip for the spacer. Make sure it is larger than the bolt that goes into the crank or you will mess up the cranks threads.