I was replacing the clutch springs on my 2002 ZR800 this morning and ran into some trouble. I just bought this sled a few months ago and am not sure if the clutches have ever been removed. I was attepting to remove the driven and it was a hard to move on the jackshaft. I pulled the keyway with a magnet and started to rock the clutch back and forth with the parking brake set. It would move a little in each direction and so I started to pull it from the shaft as I continued to rock it. It tighted up after moving about 1/8" so I pushed it back on to try again now it will not move. I cannot get it to even rock let alone slide on the shaft. Any ideas as to how I should tackle this. I sprayed it with penetrating oil and warmed it slightly with a propane torch and it still will not move. Is there a safe way to pull a driven or should I just heat it up some more. I do not want to have to take it to the dealer because I am on a tight budget right now.
You can tip the sled on its side and spray some penetrating oil on it and allow it to sit overnight in order to let the oil work its way between the shaft and the clutch. Then you can heat it up a little and try it again.
That being said, I had a stuck secondary on my Cat and couldn't get it off for the life of me. Finally I broke down and got the secondary puller that Cat recommends and it came off with ease. If you can't borrow the tool from your dealer, you should consider buying one. They are worth their weight in gold!!! You don't have to worry about damaging the clutch let alone all of the frustration.
Make sure to put some anti-sieze on the shaft before you put the secondary on again.
Well I got it off today. I had my uncle come over to help load it as I could not drive it onto the trailer. He was looking at it and came up with this idea. I was able to remove the keyway last night when I was working on it so what we did was put the bolt back in and install an old belt. I then started the motor and while holding the brake I "bumped" the throttle just enough to engage the primary for a split second. I did this like 3 times and it came loose. Not sure if this was the best or safest way but she came loose with no damage. It appeares that the prvious owner had never had the secondary clutch off the sled as recommended for greasing. She is all back together now and all appears to be fine.