Installing 911 Clutch Cover - Issues

[Frostbite]

I finally got around to ordering a 911 cover for my sled. I went out to the shop to install it and ran into a couple surprises.

1. I went to remove the primary clutch with my new blue metric puller and unlike my 09 M8, there is no large hex head bolt in the end of the clutch. There is what appears to be a huge Torx type head bolt recessed inside the primary. Apparently I have to remove that first before I can install the clutch puller. I checked my tool kit and there is nothing in it I can use to remove the Torx head bolt. What tool do I need? What is it called and what size is it? Is there a Cat part # for this? It's WAY larger than any of my Torx heads.

2. To install the 911 cover you have to remove what I will call the "tower shaft" that the primary spring slides over. Once again, this shaft has one huge nut recessed into the primary (no way to use a wrench). Of course, I didn't have a tool to remove this either. So, I did some forum searching and found Thunder Products sells a Jam Nut Tool for $39.99. So, I had to order that super huge and deep socket to be able to remove the "Tower Shaft". It's on the way.....

3. While I was at it, I was wondering if it would be possible to install the 911 cover and it's shaft with the clutch still installed on the sled? I would have to have a bar between the clutch cover mounts while loosening and tightening the Tower Shaft nut but, it doesn't seem much different than what I do when use a clutch puller, other than the clutch cover would be removed in this case which could potentially allow the aluminum clutch cover mounts to bend if the that tower shaft nut is super tight as I suspect (I will heat it up before trying to remove it). I am thinking about this because I don't have the required "Grunt Tool" to hold the clutch that Thunder products says I am supposed to have when it's removed. What do those of you who have installed a 911 cover think of the idea?

 

[0neoldfart]

A couple answers...

The Torx you need is a T55 to remove the primary clutch bolt.
Also, I would recommend the clutch holding fixture mounted on the bench or in a good vise - I've never seen a spider nut come off easy on a Cat, and you will NEED heat.
Lastly, make sure you get the clutch balanced after installing the 911 cover - your crank will thank you.

 

[Frostbite]

Thank you for the info Oneoldfart.

Who do you suggest for primary balancing? I was thinking SLP

Also, where would I order the clutch holding fixture? I have got by without one for years but, it sure would be nice to have one. Hopefully, they work for more than one brand of snowmobile?

Now to search for a T55 Torx bit....

I turns out I had T45 and T50 but, no T55. It's on the way now!

 

[clutch]

The torx is actually T60. The tower shaft does not come off, only the spider jam nut and as one old fart indicated they are tighter than a nuns c**t. It will require heat and a holding fixture. SLP sells one. They can also balance your clutch.

 

[Insaneboltrounder/sjohns]

i took mine to the dealer to get that shaft out... its a mean one !

 

[Frostbite]

Dang...I just got on Ebay ans ordered a T55 and now it looks like I will be ordering a T60 as well.

So, would my best plan be to pop of the primary (if it was only that easy) and bring it to a dealer to install the 911 cover

or

Send the primary and 911 cover to SLP to install and balance (if they would do that)?

 

[Insaneboltrounder/sjohns]

the cover is easy... the shaft not. Take to dealer

 

[Frostbite]

Got it!

 

[kidrman]

Glad someone caught the torx size. I have a t60 if you need one this weekend Lee.

 

[Frostbite]

Thank you but, I have one on the way.

I sure hope we get better snow this year!

I will send you a PM.

 

[boondocker97]

Did the cat clutch puller colors recently change? I thought the metric one you needed for the 2010+ 800 ho was green. Mine is anyway.

 

[Frostbite]

I sure hope I have the right one it's blue and blue can be!

Here's a link to the one I have!

http://countrycat.com/ccstore/index...utch-puller-2007-2016-snowmobile-wildcat.html

 

[Betterview]

I finally got around to ordering a 911 cover for my sled. I went out to the shop to install it and ran into a couple surprises.

1. I went to remove the primary clutch with my new blue metric puller and unlike my 09 M8, there is no large hex head bolt in the end of the clutch. There is what appears to be a huge Torx type head bolt recessed inside the primary. Apparently I have to remove that first before I can install the clutch puller. I checked my tool kit and there is nothing in it I can use to remove the Torx head bolt. What tool do I need? What is it called and what size is it? Is there a Cat part # for this? It's WAY larger than any of my Torx heads.

2. To install the 911 cover you have to remove what I will call the "tower shaft" that the primary spring slides over. Once again, this shaft has one huge nut recessed into the primary (no way to use a wrench). Of course, I didn't have a tool to remove this either. So, I did some forum searching and found Thunder Products sells a Jam Nut Tool for $39.99. So, I had to order that super huge and deep socket to be able to remove the "Tower Shaft". It's on the way.....

3. While I was at it, I was wondering if it would be possible to install the 911 cover and it's shaft with the clutch still installed on the sled? I would have to have a bar between the clutch cover mounts while loosening and tightening the Tower Shaft nut but, it doesn't seem much different than what I do when use a clutch puller, other than the clutch cover would be removed in this case which could potentially allow the aluminum clutch cover mounts to bend if the that tower shaft nut is super tight as I suspect (I will heat it up before trying to remove it). I am thinking about this because I don't have the required "Grunt Tool" to hold the clutch that Thunder products says I am supposed to have when it's removed. What do those of you who have installed a 911 cover think of the idea?

You are on the correct path with removing the clutch. It is almost a virtual guarantee you will break the clutch arms trying to remove the nut while on the motor.
You will like the 911 cover. I put one on my sled along with the adjustment nut for belt spacing and really enjoy the buttery smooth engagement and low speed shifting

 

[Frostbite]

Thanks Betterview, I have wanted one for quite a while andI finally did it. Once I can get the primary off, I will take it to the dealer to have the spider nut removed and the 911 kit installed. Then I will send the clutch to SLP for balancing (unless I come up with a better place between now and then).

I guess i should have asked the question sooner. Knowing that I would have to take it to the dealer, I could have saved myself from having to buy the $55 (with shipping) spider nut socket. Oh well, maybe the dealer will need it?

 

[0neoldfart]

My apologies...

Frostbite, my apologies regarding the incorrect Torx size - I had a momentary lapse (comes with age I guess).

 

[boondocker97]

I sure hope I have the right one it's blue and blue can be!

Here's a link to the one I have!

http://countrycat.com/ccstore/index...utch-puller-2007-2016-snowmobile-wildcat.html

According to the description it should work for you. I see it supersedes a few different pullers. Maybe they cut a shoulder different on it or something so it works on the Wildcat UTVs too and that's why they changed the color. I've had mine since about 2010 and it was a big deal then to make sure you had "the green one". I'm sure it's fine.

 

[Frostbite]

No problem Oneoldfart, now I will have a T55 and a T60.

I had no idea I would need a T60, Spider Nut and Clutch fixture to install the 911 kit. I wish I could send my Primary to Thunder Products and have them install the 911 kit, balance the clutch and send it back. I may have to call Lon and suggest that.

 

[fast8seccamaro]

You can make all the tools. A piece of flat plate with square tbg welded on the back will slide into your bench vise. Drill the holes thru the plate and bolt you clutch to the plate on the back side of the clutch. For the socket, I just took the right size deep socket. Cut off the end where your ratchet goes, and weld another deep socket onto it. Basically you have the length of 2 deep sockets. A little heat on the nut and good to go. You might have to re-shim your spider. I suggest getting the hard machine washers from 911. I squeezed out the factory washers while riding and lost my primary belt side to side clearance, bsically had cruise control. If this is the only clutch You'll ever rebuild and change covers, your prob way better off just to send it out lol it is alot of work

 

[WhiskeyTee]

The video they have on the site for installation is pretty misleading as far as the difficulty to install this cover. Glad I hadn't ordered one yet! Was on my list for next offseason mods budget.

 

[dgibbons]

Just for anyone else reading this (Frostbite, you may be in a remote spot), but you should be able to find a T60 at any auto parts store or hardware store. I bought my T60 (and a T70) at an O'reilly's but have also seen them at Menards / Lowes. Shouldn't need to be a special order item most places