Lower Sprocket Removal Problem

[Blackhawk]

Hello,

I am trying to gear down my 2012 Pro RMK 800 163, but the lower chaincase sprocket will not come off the shaft. The bolt is removed (it had a ton of loctite on it) but the sprocket is stuck, its never been off before.

I tried heating the sprocket up with a heat gun and got it really hot, but it still didnt come out (thinking that loctite may have been on the splines).

Any suggestions?

Thanks!

 

[Laundryboy]

wouldn't just a basic cheap gear puller from harbor freight work?

 

[Blackhawk]

Good suggestion, I tried a 3 armed bearig puller this evening (not sure if that is what you meant), the problem is that the chain is still on because you can't get the chain off unless you can slide the gear with it. This means that the 3rd prong/arm of the bearing puller won't get behind the gear.

Any other thoughts? I am thinking of trying a flywheel puller in hopes I can maybe get a large fender wash and nut behind the circular holes in the sprocket, but not sure if this will work either. Running out of ideas...

Any pictures / links to tools that may help would be appreciated!

 

[wjl]

Here is a simple puller I made it worked for my ski doo xp for gears and brake.
Take a piece of steel 1/4" thick by 1" wide length ??? And drill a hole in the center and tap for a 5/16 bolt and then drill the outer holes 1/4" and in your case just wide enough to fit in the spokes of the gear. You should get the idea.
Have you tried taping it with a hammer and wood in between. Try to tap the gear inward to brake the bond.

 

[TRS]

I may have missed it in your post, but you should be sliding the top sprocket and the bottom sprocket off at the same time? If you don't, the bottom sprocket will bind. Don't forget to remove the jack shaft o-ring.

 

[Blackhawk]

Thanks for the suggestion wjl! I will see if I get a chance tomorrow evening to work on it.

The o-ring is removed and the top gear slides freely, but the bottom gear does not budge, I followed the service manual procedure for this and I've taken chaincases apart many many times (not on this chasis before), never had one where the gear was stuck to the drive shaft, normally they slide right out. I tapped on the bottom gear a bit, not too hard but hoping to free it, I think a puller is going to be what I need.

Thanks!

 

[TRS]

Have you tried a couple rolling head pry bars after it was heated?

 

[OnlyPolaris]

did you remember to back off the chain adjuster so there is slack in the chain?

 

[Blackhawk]

Thanks for all the comments, I was able to remove it last night.

I ended up using a harmonic balance puller, just used two bolts to pull it out.

The biggest pain was getting a fender washer and nut behind the sprocket, used a jam nut taped to a fender washer, a regular nut didn't quite want to fit past the ribbing on the inside of the chaincase.

All back together now with 19/43 gearing instead

Thanks!