Removing Secondary Clutch from shaft - Snowmobile Forum: Your #1 Snowmobile Forum

Joelk · 10-19-2009, 10:23 PM

I have a couple old El Tigres, a 77 and a 79 that I am working on. Right now trying to get the best parts from both sleds and make one "good" sled out of the 79. The clutches appear to be the same on both, but the 77 clutch appears to be it better shape.

I removed the bolt from each secondary clutch and sprayed PB blaster in the keyway slot. The clutch came right off of the 77, but I have not been able to get it to budge on the 79. I hit the shaft with a large brass punch, with a helper pulling on the clutch, but to no avail. Tried mild heat, also to no avail.

Any tricks to getting it loose/off?

Thanks, Joel

justmytailights · 10-19-2009, 10:31 PM

tip the sled on the right side,pour transmission fluid tnto the hole on the clutch,refill as necessary and the clutch will pop off

Joelk · 10-20-2009, 08:51 AM

Thanks for the reply.

Not at the sled right now and was working in semi dark conditions when I made initial attempt to remove.

Where is the "hole on the clutch?" Keyway on shaft?

Will Trans fluid will work better than PB Blaster?

Will try that but if no success. Any other suggestions?

**RJ Gleason** · 10-20-2009, 12:25 PM

He means the bolt hole in the center.
PB Blaster will work better than atf, tip sled on it's side so that the oil stays in there better.

Then heat gently with a propane torch applied to the hub of the clutch, not to the steel shaft.

Joelk · 10-20-2009, 04:02 PM

I had it tilted on right side with PB Blaster in the keyway slot. Put propane torch on it(hub, not the shaft) for seveal minutes again today and it still does not budge.

**RJ Gleason** · 10-20-2009, 04:23 PM

Patience grasshopper.

Joelk · 10-22-2009, 09:33 PM

I put a propane torch on it for 5 minutes today. It still won't budge.

How many days does it take for the PB Blaster to work?

**RJ Gleason** · 10-23-2009, 02:30 AM

Well, it took me 3 weeks to get the one off of a 92 Wildcat.

Joelk · 10-28-2009, 08:58 AM

I have been trying it every day and it still won't budge.

Any other suggestions beside patience? Is it really likely to come loose if I just wait longer?

I can't run the 79 with the secondary clutch the way it is. 2 of the clutch buttons are sheared off and the spring is out of the hole it is supposed to be in, so that it does not apply twisting force to the hub.

It looks like the clutch would be OK if I could get the buttons replaced and the spring back where it should be.

I have been trying to dig/pull the remaining part of buttons out without success.

Any suggestions on how to get the bottoms out with it still on the sled?

I have not yet tried to get the spring back into the hole. Easier to access the button remnants with it the way it is. I am hoping that I may be able to work it around and get in back in place using a couple pairs of needle nose vice grips. Anyone ever had success doing this with the clutch on the sled?

Any other suggestions?

Thanks, Joel

**RJ Gleason** · 10-28-2009, 11:46 AM

Take the snap ring off and you can then get the ramps turned enough to get the outer piece off. That will make getting the plastic parts of the slide buttons much easier to get out and you can then also change the spring mounting hole.

agfirecat · 10-28-2009, 09:00 PM

you gotta somehow get the keyway tapped out towards the end of the shaft if its pushed way in it wedges the clutch tighter.

Joelk · 10-28-2009, 09:07 PM

My patience ran out.

A buddy of mine had a really big 2 jaw puller and we used it on the secondary clutch today. Tightened it up enough to distort the pulley quite a bit and beat on the puller/shaft and also put 2 propane torches on the pulley for about 10 minutes before it finally started to move. Even after it moved slightly, still had to keep pulling and beating to get it off. When I got it off, the shaft was rusted, but certainly not extremely severe. Based upon how hard it was to remove, I expected it to be much worse. I think I would have waited years, and it would not have pulled off by hand with just PB Blaster.

While pulling it, I was trying to limit the amount of distortion to the pulley, but figured it would probably be damaged in the process, but I think it may be OK. If it is distorted, it is very slight, surprising given how much I had to torque on it. Probably won't need/use it since the other clutch is complete and in good condition and I also have other clutches from other sleds I could use if needed.

**RJ Gleason** · 10-29-2009, 12:09 PM

If you warped it even slightly, DO NOT USE IT!!
When you put another on on there, use some Never Seize on the shaft.

Joelk · 10-29-2009, 04:08 PM

It looks OK to eyeball it, but if I have occasion to want use it again I will watch it while rotating on the shaft to make sure it is running true.