11-07-2009, 01:13 PM
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Clutch removal question
I need to pull the motor and I have the secondary off and the primary outer off Im not sure on how to get the inner off. I dont want to hurt any thing.
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06 outty 800 MRRPM 840 gen 2 cams 09 intake PC3 engine oil cooler fan over ride snorkled full skids Aluma Tech CV Guards ITP 212 26" terra cross Piaa HIDs secondary radiator digital engine temp heated hand and thumb BRP fender extensions Fasst Flexx 14deg bars Rox Anti Vibe Risers Cycra Hand Guards and bark busters Moto Comm Camera stage two Crutchfields front and rear
07 Renegade 800 Rox anti vibe risers Aluma Tech external oil filter and cooler
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11-07-2009, 01:19 PM
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there is a puller tool you can get from the dealership. I have seen some tools someone had made with a solid push rod and a bolt.
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'09 Renegade X 800R
Mud Industries Snorkels
Engine Ice
Comet Clutch
Twin-Air
Full Muzzy
PC V (Dual Cyl. Race)
14" SS212s
30" Silverbacks
Warn RT30
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11-07-2009, 01:34 PM
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First Name: Kjartan Gušmundur.
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Quote: Originally Posted by f419sr1
I need to pull the motor and I have the secondary off and the primary outer off Im not sure on how to get the inner off. I dont want to hurt any thing.
PT# 529035746 CLUTCH PULLER
It is the gold colored one 
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11-07-2009, 01:36 PM
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get an M14x1.5 bolt, 80 mm long, with 35 mm of threads, and a 10 mm rod, 90 mm long. drop the rod in the hole, tighten the bolt.
or you can tip the bike on its right side a bit, take an M14x1.5 bolt and wrap it with thread tape, fill the inner primary hole with water, tighten the bolt. you can also use grease instead of water, but it takes more work to clean it out.
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11-07-2009, 01:51 PM
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11-07-2009, 02:08 PM
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If you can get hold of this stuff:
3M? Wire Pulling Lubricant Communications
You don't need to tip the machine on the side. The 3M cable pulling lubricant(used by electrician) is a water based gel that is firm enough so it won't drip out before you stick the M14 bolt in(as stated above) and the beauty of it is that it's very easy to remove after you are done. Used it a lot on snowmobiles when I needed to remove the drive clutch. I guess you could use cornstarch to just make some gel stuff for this purpose also.
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11-07-2009, 02:14 PM
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Thanks for the quick responce. I called the dealer They told me they couldnt answer any questions until Tue. Nice way to do business.
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06 outty 800 MRRPM 840 gen 2 cams 09 intake PC3 engine oil cooler fan over ride snorkled full skids Aluma Tech CV Guards ITP 212 26" terra cross Piaa HIDs secondary radiator digital engine temp heated hand and thumb BRP fender extensions Fasst Flexx 14deg bars Rox Anti Vibe Risers Cycra Hand Guards and bark busters Moto Comm Camera stage two Crutchfields front and rear
07 Renegade 800 Rox anti vibe risers Aluma Tech external oil filter and cooler
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11-07-2009, 02:27 PM
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Lol so it takes them 2 days to find the info. 1 for finding the book and another one to search in it.
Anyway just glad to help. that what this site is for.
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11-07-2009, 04:30 PM
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Guys, this is all great info. I would have never thought of using either water or a viscous fluid to pop that primary off of the engine output shaft. Talk about thinking outside the box! If I ever have to do that again, I am gonna try that method. Reminds me of when I had to remove the lower pulley bolt on a ford ranger I had. Somebody online said to put a breaker bar on there and turn it over..worked like a champ! Just had to make sure the breaker bar was already against the lower cross member. Don't want a breaker bar flying around in the engine bay...its bad, bad..
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