Hi All,

I need Help. I broke the rear swing arm on my 325 Tboss 2000. Snapped it right in half! Thats what i get for trying to jump a utility bike. Landed the jump [img]i/expressions/face-icon-small-smile.gif[/img]. drove for a little while after in the woods hit a few small jumps ripped some small hill climbs. then i looked down and the right side right near the weld on the arm was cleanly snapped. Needless to say i got the bike home rear end swaying all over. Now i ordered the new swingarm and went to take it out, well the left side bolt (1"¼) the screw side on the left swing arm bolt is right behind the clutch pully so i need to pull it . I guess what i am asking is where the heck do i get the right size pully puller ! HELP!!!!!!!! I wanna ride this weekend !

 

unfortunately, you have to pull both clutches and pull of the rear clutch cover panel. The secondary clutch off the tranny will usually just pull off by hand once you pull the bolt out. However, for the primary clutch on the engine, you will need a clutch puller, which is basically a large bolt with threads half-way up. I don't recommend using a pulley puller as you could crack the outsides of the primary clutch casing, it's not that strong. You can get a clutch puller for a polaris for about $20 out of several catalogs, such as Dennis Kirk, or hpd-inc.com or hotseatperformance.com. These places should have a puller. Or maybe you have a nice dealer who will let you borrow one for an hour or so.

 

Yep. if you need to get that off and fixed before the week-end, a nice Polaris mechanic is your only hope.

 

Hey I just had my scrambler swingarm out, cracked it. My primary clutch I usd a 3/4 inch fine thread bolt, and a small piece of all thread to get it off. The secondary usually will pull right off. I think the 3/4 bolt was 3-1/2 in. long, and the all thread was 1/2 diameter and about 4in. long. Just put the allthread in ,tighten the bolt till tight ,tap it with a hammer ,and tighten again, tap it again, till the clutch pops off. Goodluck.

 

In a pinch, you can even use a trailer ball with a 3/4 inch shank. These are almost always fine thread, which matches the pitch of the threads cut inside the bore of the pulley. Just be sure it is fine thread. If the shank isn't long enough to reach the crankshaft, put some washers in the bore, and try again, Be careful not to let the washers fall over inside there, though.

Farmr

 

OK ,
Well here is how things are going . I went and got the swingarm today at the polaris dealership. While I was there I inquired about a clutch pully puller . They had one so I bought it .The right tools is all thats needed. I got to my buddies house at about nine and we went at wrenching. He has a banshee and he was getting it tuned for tomorrow. The first thing I did was head right to the pully with the tool. By the way mine is course thread. I stick it in the hole and the damn shaft on the tool was to long. The threads were like an 1/8 in. away from being able to be thread into the pully. I asked my buddie for a hack saw. "Nope" of course not, so I decided to put the tool in the vice shaft side up. I ended up using a metal file to cut through this thing . Took 20 min. Stuck it in and put a rachet on it and bang the pully came right off. The back plate is plastic and it has 3 screws holding it in . Pulled that back plate right out of the way.Tomorrow morning going to rent to big sockets. Ill be riding by noon.

I got off ebay, a fox rear shock (piggyback res) and tall struts off a 400 sport. Put those on tonight seemed sweet!

 

You must mean the rear pulley?
The front pulley on mine is fine thread, so I was going by that.
The rear, I always got off without a puller.

Remember to grease the splines a little before you put it back on. Not too much, you don't want any excess grease getting on the belt. Anti-sieze is probably the best stuff for that.

 

Well all is on,
Finished at about 3 went got some oil and things. Dropped off the 1 3/4 in socket drive and wrench. (Correct what i said in a previous post 1 ¼ in.) to a buddie that I picked it up from this morning. got back to House at 4. Rode out in the woods for an hour or so. Was mint.

Thanks everyone, hmmm didn't no i was a polaris mecanic. Anyone hiring! With the right tools!

 

Good for you! Glad to hear everything works now. Just remember, it is an ATV, not an airplane LOL [img]i/expressions/face-icon-small-smile.gif[/img]