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

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

 

Keith...
If you are talking about the secondary clutch..(the one on the tansmission) I know this isn't the politically correct way to do it, but after I removed the bolt... I threaded it back in about 1/2" without the washer on it... Then took a dead-blow hammer and hit quarely on the head of the bolt while pulling on the outside of the pulley... After about 4-5 "taps" it slid right off....
Just don't get over aggressive and beat it to death with a 16 oz. nailing hammer....

 

Thx. But the drive clutch is the one off the crankshaft. The driven clutch is off the transmission. I am trying to get the engine clutch off.

 

Just go to the dealer and spend the $25-$30 and buy the puller. The cluthes have a taper on them and you will see how hard it is to get the cluthes off even with the puller. It is really pressed on there tight.

JP

 

Isn't that strange, I borrowed one from a local shop yesterday to pull mine off my SCR500, afterwards I went to the hardware store and bought two bolts and made my own for next time, what you need is a 6"x3/4"-16 tpi(fine thread) and a 3"x5/8" bolt.

1. cut the head off the 5/8" bolt
2. line the bolts up end to end and weld
together paying close attention to get
them centered and straight, I used two
V-blocks, one with a 1/16" shim under it
to split the 1/8" difference.

It was identical to the one I borrowed, hope that helped you out. If you have any other questions about procededure or what I used just post it. By the way, this set up only cost me 3 bucks and some change.
Take it easy and ride safe.


[This message has been edited by SCRAMBLINGCRAZY (edited 02-01-2000).]

[This message has been edited by SCRAMBLINGCRAZY (edited 02-01-2000).]

 

I took my Scrambler to the dealer and asked if I could borrow the tool to take of the clutch. I used it right in the parking lot. Once it was threaded in I took a hammer and hit the tool a few good times to break the seal and it came right off. Just take your atv up there, striped down and ready to do the work. I have a great relationship with the dealer and I do all of the work myself and when I need a tool I just use theirs. Good luck,

 

I went ahead and made the tool as described above. It worked great and was nearly free. One thing to note however is I ran out of threads on the 3/4 UNF bolt threading it in the clutch. I placed a small 6 pt. socket inside against the crank and then I was able to pull it off no problem with my 1/2" impact gun. Either go with a bolt longer than
3" or run a die on the 3/4 X 6 bolt and add a few threads.

Thanks, for the input guys. You saved me a few bucks.

Keith

 

One other thing that can be used is the 3/4" bolt from a gear puller - it is more than long enough, threaded the whole length, and hardened so you don't have to worry about bending or pulling threads. You can turn around and use the gear puller on the tranny clutch - just put a little pressure on it and smack it with a hammer - jumps right off.