 |
07-11-2011, 12:51 PM
|
 |
Junior Member
|
|
Member #16694
Join Date: Jul 2011
Posts: 5
|
|
|
polaris rebuild
Hi im new here and I have a 96 trailblazer that i am trying to rebuild for my dad. I have it ripped down to the bottom end but still in the quad. the quad shattered the piston skirt and put aluminum fragments all through everything. I am trying to get the clutch assembaly off of the block so I can flush the bottom end out and see what all is bad but I cant figure out how to remove the clutch? any help would be appreciated! thanks
|
07-11-2011, 01:28 PM
|
|
Junior Member
|
|
Member #16694
Join Date: Jul 2011
Posts: 5
|
|
anybody home? 
|
07-11-2011, 01:52 PM
|
 |
Polaris ATV Legend
|
|
Member #3687
Join Date: Mar 2010
Location: east arkansas
Posts: 2,302
|
|
|
You will need a Polaris primary clutch puller. You can buy aftermarket puller for around $20-30. Or build it. I don't remember the size diameter of bolt 5/8" or 3/4" fine thread about 10" long. Get a piece of all thread rod with a nut welded to it. First remove the bolt in the center of clutch. Then thread the puller into the hole and tighten and the pulley will come off.
__________________
1995 GMC 1500 Ext. Cab Z71( new motor 3 yr warranty unlimited mileage, on the road again  )
2008 Pontiac Grand Prix
1996 400 Explorer 4x4( project purchased 12-30-11)
1995 425 4x4 Magnum
1998 Sportsman 500 4x4(parting out)
1999 Kawasaki 220 Bayou 2wd
|
07-11-2011, 02:03 PM
|
|
Junior Member
|
|
Member #16694
Join Date: Jul 2011
Posts: 5
|
|
|
so is the primary clutch threaded onto the crank or is it a press fit? the way you explained it it sounds like it is has left handed threads and turns off. is that correct?
|
07-11-2011, 02:43 PM
|
|
Polaris ATV Legend
|
|
Member #3687
Join Date: Mar 2010
Location: east arkansas
Posts: 2,302
|
|
|
It is a press fit. It has a bolt holding it on in the center. Remove that bolt. It has about a 9/16" or 5/8" head on it. After removing that bolt thread the puller(threaded rod) into the clutch. The threads hold the clutch and as it bottoms out on the crank it will press the clutch off the puller. It is right hand threads. The slotted nut on the flywheel side of the engine is sometimes left hand thread. I hope this makes sense.
__________________
1995 GMC 1500 Ext. Cab Z71( new motor 3 yr warranty unlimited mileage, on the road again )
2008 Pontiac Grand Prix
1996 400 Explorer 4x4( project purchased 12-30-11)
1995 425 4x4 Magnum
1998 Sportsman 500 4x4(parting out)
1999 Kawasaki 220 Bayou 2wd
|
07-11-2011, 03:03 PM
|
|
Junior Member
|
|
Member #16694
Join Date: Jul 2011
Posts: 5
|
|
|
yep that pretty much cleared it up. im kinda new to the polaris setup but im learning
|
07-11-2011, 04:07 PM
|
|
Polaris ATV Legend
|
|
Member #3687
Join Date: Mar 2010
Location: east arkansas
Posts: 2,302
|
|
|
You will learn. I learn everyday and been working on 4 stroke Polaris for about 12yrs now. I have a total of 11 4 wheelers and all but 1 are Polaris. Most of them I am parting out and thats when you start learning. LOL.
Good Luck on the rebuild.
__________________
1995 GMC 1500 Ext. Cab Z71( new motor 3 yr warranty unlimited mileage, on the road again )
2008 Pontiac Grand Prix
1996 400 Explorer 4x4( project purchased 12-30-11)
1995 425 4x4 Magnum
1998 Sportsman 500 4x4(parting out)
1999 Kawasaki 220 Bayou 2wd
|
07-11-2011, 05:11 PM
|
|
Junior Member
|
|
Member #15780
Join Date: Jun 2011
Location: richmond, va
Posts: 26
|
|
|
Yes sir re bob. am doing the same rebuild for the second time on this 96 250 TB. There is a special puller for that job!!! Do not try anything to get that clutch off without the proper puller. I did find a friend that had the right puller and he let me use it. Works great and it's real easy. I just put the clutch assembly back on and finally got the piston and rings back in the cylinder today. That's a tuff one
|
07-12-2011, 12:49 PM
|
|
Junior Member
|
|
Member #16694
Join Date: Jul 2011
Posts: 5
|
|
Thanks for all the help guys! this is my first polaris build. it was my boys quad till it blew up then i decided to get him something a lil more his size and a lil more sporty so i got him a 300ex and he loves it. then i decided to try to bring the 250 back to life and give it to my dad. Id like to get my mom and dad out with me and the wife and kids. I got the whold family outfitted now. I run a yamaha yfz 450 r, my wife runs a yamaha 350 warrior, my sone has the honda 300ex and my lil girl runs a kasea 90. heres a lil video i made of my family riding with our friends. if you dont like metal music turn it down! lol. 
|
|
Lower Navigation
|
|
|
| Search tags for this page |
|
1993 polaris 250 4x4 head bolts torque, 1994 polaris 400l 4x4 flywheel nut, 1995 sportsman 300 piston, 1996 polaris xplorer 300 clutch puller, 1996 polaris xplorer 300 cylinder head, 94 polaris 300 rebuild, bolt size for flywheel puller 1995 polaris magnum 4x4, how to get remove cylinder from block on polaris trailblazer atv, polaris 250 bottom end rebuild, polaris 250 trailblazer hole in piston, polaris 300 4x4 piston, polaris 300 atv head bolt torque, polaris 300 head torge, polaris 90 head torque, polaris magnum 350 rod, polaris xplorer 400 primary clutch torque, rebuilding bottom end polaris 250 motors on youtube, u tube polaris rebuild, what size is bolt in polaris xplorer dive clutch, xplorer 300 head bolt size
Click on a term to search our sites for related topics.
|
| Thread Tools |
|
|
| Display Modes |
 Linear Mode
|
|
Posting Rules
|
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
HTML code is Off
|
|
|
|
|
All times are GMT -8. The time now is 08:06 AM.
