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Secondary clutch removal issues

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30K views 8 replies 4 participants last post by  Hoverhog  
#1 ·
Has anyone built or know what size the puller diameter and thread pitch is for the secondary clutch EBS
On a 2004 sportsman 500 HO.
I pulled the Center bolt and the clutch will not come off.
 
#2 ·
I have never needed a puller or the secondary clutch. I have seen them advertised though. They are just on a splined shaft so it should pull right off. Wouldn't take much corrosion to bind it up though. I think the secondary would need a 3/4 rod, but I don't know the thread size.
 
#3 ·
Ok I will keep working at it
I had to destroy the primary clutch to get it off
The threads in the primary clutch were nonexistent so I had to use a three
Jaw puller to get it off. When it finally came off it was very violent it flew across
the garage.
So I purchased a niche primary clutch non ebs the same as what I removed
Upon looking at the secondary clutch I have discovered it is actually an EBS clutch
So the quad has a non EBS clutch driving a secondary EBS clutch anyone had this setup before lol
I’m going to return the primary non ebs clutch and put the proper clutch on the quad
So now I have thoraly confused you all and my self is there anything else I should be considering
 
#4 ·
Don't need a puller for the driven clutch. If its stuck just whack it lightly with a hammer while pulling on it or put a bar behind to hold a little pressure against it while vibrating it. If it still won't come, spray some PB Blaster in the shaft and let it soak a while before trying again. Just had the same issue today with a RZR I am refurbishing. PO had swamped it and got mud and water in the clutch housing at some point. With a little persuasion it will come off. Be sure to clean the shafts and clutch splines with a wire brush before reassembly. A very light coat of antiseize will prevent it from sticking in the future.
 
#7 ·
I've had tight secondary clutches

I got the first one off by spraying WD40 into the shaft hole, screwing a long bolt into the shaft, prying behind the clutch with a piece of thin lumber and tapping on the bolt with a hammer. When I got it out about half an inch, I sprayed the shaft behind it with WD40 then tapped the clutch back onto the shaft with a polycast dead blow hammer - I worked it back and forth a few times and it slid right off - now I have a puller
 
#8 ·
I have never had one that stuck so I don't have a puller for the secondary. Maybe I should find one before I run into an issue. You can never have too many tools right?