If its not rusty inside there, you might be able to pull it without using a puller. I was able to get mine off with a few taps of a rubber mallet. I know you can buy clutch tools at Dennis Kirk.

 

does anybody have and pictures or videos of them removing the clutch and sealing the housing with silicone?

 

You can use a 3/4"-16 bolt 6" long. Clutch fits on crankshaft using a taper fit.
Screw the bolt in until it contacts the end of the shaft and then, while keeping the clutch from turning, torque the bolt. Impact wrench helps. Hit the end of the bolt with a hammer while it's torqued. You have to break the tapers apart and then it falls off. If it's never been off it could be a bitch.The greater the torque on the bolt the easier it will come off. Rear clutch is splined and only a bit of rust would make it hard to remove.

 

The dealer wants $40. I think I'm going to bite the bullet and buy it. I will be doing a lot of water crossings and it will probably be worth it in the long run.

 

Expensive bolt for the number of times you'll use it but it's your dime.

 

Primary clutch removal tool

I used a 3/8" drive 6" extension plus a 3/4"-16 3" bolt that I purchased at Trator Supply, I had to grind aprox. 1/2" off the square end of the extension. After removing the bolt that holds the clutch on I inserted the extinsion until it stops, then tightend the bolt until the primary clutch popped and it was done. Cost about $8. This was done on a 2009 Polaris sportsman 800 EFI. Wishing you success in all your maintenance and repairs.

 

primary



If you havent all ready purchased a removal tool, read my post above. Goodluck!

 

Clutch removal trick

To remove the primary clutch no need to buy the 40.00 bolt/tool simply get a trailer hitch ball with 3/4" shank and a short 3/8" socket extension with a short socket of any smaller size and a pipe wrench then insert the socket with extension into bolt hole then thread in trainer hitch ball and tighten the ball with pipe wrench. You will need to thread a long bar through the large openings on clutch not the small ones to avoid damage and wala.

 

To remove the primary clutch no need to buy the 40.00 bolt/tool simply get a trailer hitch ball with 3/4" shank and a short 3/8" socket extension with a short socket of any smaller size and a pipe wrench then insert the socket with extension into bolt hole then thread in trainer hitch ball and tighten the ball with pipe wrench. You will need to thread a long bar through the large openings on clutch not the small ones to avoid damage and wala.

This is essentially what I did, but with a 3/4"-16 bolt that was 6" long. I also used a pry bar between the clutch and a hole in the foot board to keep the clutch from rotating. Get a breaker bar and a piece of pipe for leverage and it should pop right off. Mine came off a 96 easily.
Just a note, don't use a socket or extension that you really need as they might not want to separate after you use them!
JJ

 

I've b een using the same polaris clutch puler for 30 yrs, same as snowmobiles

 

I have a 2000 sportsman 500. Tried a 3/4 bolt and was too thick to fit in the shaft. There is a new clutch on the machine but need to take it off to rebuild the engine. I just bought this machine so have no idea if it is factory or a ftermarket clutch. Has anyone else had this problem? If so what size bolt will work?