clutch removal tool stuck in clutch - Snowmobile Forum: Your #1 Snowmobile Forum

odiez · 05-31-2009, 03:57 PM

ok, so I'm trying to pull the primary off my '99 Vmax 500 and it's not coming off. I got the puller threaded in almost all the way and the clutch won't budge. I tried to get the puller out and I can thread it out of the clutch all the way but then it won't come out any further. It's loose but still stuck somehow. I've tried pulling on it with visegrips and and prying it out but still can't get it out.
What could be holding it in there like that?
Any ideas?

JheLrey · 05-31-2009, 06:46 PM

I've had clutch bolts do that to me... Keep reversing it out maybe with a drill or something a little higher speed. At the same time, take a wrench that you can put on the shaft of the bolt, but smaller than the head and pull out at the same time.

odiez · 05-31-2009, 07:57 PM

I was able to get the puller out but I ended up breaking the small end of the puller off inside the crankshaft. It got bent in there and now it's stuck and I don't know how I'm going to get it out. The clutch is still on the shaft too.
This has not been a good day.

**smallengineguy** · 06-01-2009, 07:29 AM

Use an easy-out to get it out. Drill into the end of it and install the easy out.

odiez · 06-01-2009, 12:08 PM

The piece that's broken off is loose inside the shaft. I can get a magnet on it and spin it around, but I think it's bent in such a way that it won't pull back through the hole. The whole tool itself was loose when I tried to get it out, it just wouldn't pull out, so I tried prying it out and that's when the small end of the puller snapped off.

JheLrey · 06-01-2009, 08:12 PM

You were cranking hard on it to break it... you may be able to get a bolt with the same size thread as your puller and use that and jam that against the broken piece in the clutch.

odiez · 06-01-2009, 09:48 PM

I'm starting to run out of ideas. I'm going to try to use the puller again with a piece welded on to attempt again to remove the clutch, this time using a bit of heat.

JheLrey · 06-01-2009, 11:01 PM

Were you using an impact gun to remove the clutch and drive the bolt? If not, that is your problem.

odiez · 06-02-2009, 02:55 AM

Quote:

Originally Posted by odiez

I'm starting to run out of ideas. I'm going to try to use the puller again with a piece welded on to attempt again to remove the clutch, this time using a bit of heat.

ok, to clarify this last post which was written by my son and not me..... the plan is to try the puller again with a short bolt welded onto the broken end of the puller and a water filled hole. A buddy told me the hydraulic pressure will help to get the clutch off.
I'm hoping once I get the clutch removed I'll be able to get at the broken off puller end. Maybe I can wedge it and try drilling it out. I'll be able to get a better look at it without the clutch.
Yeah, I was cranking on it pretty hard - by hand with a little persuasion, expecting the clutch to pop off at any moment, but it wouldn't budge.

**smallengineguy** · 06-02-2009, 07:00 AM

Use grease, not water. MUCH more hydraulic pressure.

odiez · 06-02-2009, 02:28 PM

If I use grease would I still need to weld a bolt on the end of the clutch remover to push against the broken end or would the pressure alone be enough to force the clutch off without welding a bolt on?

**RJ Gleason** · 06-02-2009, 02:34 PM

The pressure should be enough to do the job.

odiez · 06-11-2009, 02:02 PM

I finally got the clutch off after I put a little heat to it. The grease alone wasn't doing it.

Now the threads on the crank are mucked up on the end from the bent puller end. I started running a tap into the crank but now I'm worried about cross threading with the tap so I stopped going in with the tap. Are there any tricks to go in with the tap and not screw it up more than what it is? The threads are only mucked up about 1/2" in and then they're ok after that.

**smallengineguy** · 06-12-2009, 07:19 AM

No tricks, really. Just slowly do it. Use plenty of cutting oil. Congrats on getting the clutch off.

odiez · 06-15-2009, 02:49 AM

I tapped the crank threads and now all I need is to get the mag off so I can split the case to change the crank seals. Hindsight being 20/20 I would have taken off the nut while the clutch was still on the crank with the clutch holder on.doh!