09 800R primary clutch removal. Ya sounds simple. But have any of you guys tried pulling off the primary clutch, and the clutch pullers shears off inside clutch? Well it's happened to me moments ago. Sled still in the garage, with the primary still on motor, and well i have part of the exploded clutch puller in my hand. Was not using an impact or anything like that. So im curious as to if, this has happened to you and what you, or the dealer did with the sled. Did they have to change out the crank? I will post some pictures later if i get a chance. Thanks.
09 800R Primary Clutch, has it happened to you?
- Thread starter Ridin High
- Start date
Did you buy a cheap clutch puller? there are lots of threads on how to remove a stuck on clutch. So what to do now. First thing I would try is put the sled somewhere will it will freeze, flip it on it side and pour water down the hole. The water should seep past the puller and when it freezes and expands the clutch should pop off. You can then remove the puller with some vice grips. If you need to keep the crank from turning take a plug out and put some rope into the cylinder, when the piston comes up and pushes on the rope it will keep it from turning.
good luck
good luck
the exact same thing happened to me and my dad working on his sled.we were only using a torc wrench too. finally got it off the dirty way. pound on it, heated it up to try and pop it, then started the sled up and gave her some WOT and it come spinning off and knicked up the plastic on the bottom a bit. then we could take the stupid clutck puller out from the other side....i learned some new curse words that day =) still have not got the back shiv away from the primary though. we are going to have to find a way cause hes tinking with his clutch this week, so it should be a chore.
we bought our clutch puller from BRP
D
deaner
Well-known member
This just happened to me two days ago pulling the primary off of a buddies 08. BRAND NEW Brp clutch puller (to the tune of $65)
How much torque did you get on it before it snapped. When mine broke, I had everything pretty tight, so what I ended up doing was heating the heck out of the shaft in the middle of the primary with a butane torch. Once it was good and hot I just rotated the primary slowly and give it a few taps with a rubber mallet. She popped right off. Once it is off, the puller is only in the primary clutch.....not in your crank stub. You should be able to screw it out by hand, or with a pair of needle nose pliers.
Good old BRP and their classic junk. I love my xp, but same old BS. Blown belt after 150 miles. Took it in for warranty and they told me to pound sand. This will probably be my last doo.
How much torque did you get on it before it snapped. When mine broke, I had everything pretty tight, so what I ended up doing was heating the heck out of the shaft in the middle of the primary with a butane torch. Once it was good and hot I just rotated the primary slowly and give it a few taps with a rubber mallet. She popped right off. Once it is off, the puller is only in the primary clutch.....not in your crank stub. You should be able to screw it out by hand, or with a pair of needle nose pliers.
Good old BRP and their classic junk. I love my xp, but same old BS. Blown belt after 150 miles. Took it in for warranty and they told me to pound sand. This will probably be my last doo.
the clutch on my dads sled would not pop when we heated it with the torch.
i got lazy, i just back the bolt off a little with no belt, hot WOT and she pops the outer sheave off nice like, if you want the whole thing i cant help ya.
If you pump a little grease in the hole before you thread in the puller that wont happen, your clutch will be removed hydraulically. I know that doesnt help much now,,sorry.
I agree with the other posts....the puller is tight so there is pressure in there. Apply heat and then use an aluminum or brass bar and give it a few whacks on the center shaft of the primary from the top. Also put something against the broken end of the puller and hit it real hard and solid....repeat until something gives. Good luck! 
yeppers bbroke my clutch puller bolt off the first time i removed the primary on my 09, put the ready heater in front of it gave it the heat for 1/2 hour one good hitt with a rubber dead blow hammer she came off got lucky could have been bad if it didn't. brought the broken puller to my dealer and they gave me a new one no questions asked they said they've had quite a few breaking......i had one for 3 year probablly been used a hundred times, with out any issues.
turn sled on side, pour water in hole of primary, put about 10 wraps of teflon tape on the threads of your stock bolt. start it by hand and turn it about 10 turns. the clutch will come off.
PS: you will be threading into the second set of threads on your sliding half
I didn't have my clutch puller in the shop and I pulled my clutch off by doing the above. it should work for you.
PS: you will be threading into the second set of threads on your sliding half
I didn't have my clutch puller in the shop and I pulled my clutch off by doing the above. it should work for you.
