How can I get my belt off without damaging it?The bolt hole stripped on my secondary so the little tool won't work.There isn't any room to get your hands in there to try to manually force it open.The belt is riding up out of the secondary enough that I can't get a hold of the outer edge of the pulley.I can't retap it in the sled as there isn't enough room. :cussing:

Can u get a flathead screw driver in there to pry it off? IF not pull the sled with the car which will turn the track which turns the secondary which will pop the belt off (as long as you already have it part way off) Thats how i got my belt on.

Put some muscle into it. :D

If you hook a car up to it, don't let anybody see you. Just think if you where on the trail and you had to change the belt, would you walk back to get your car! it'll come off, just work it.

i am sure you can get it off without that tool....turn the secondary clutch and shove the belt down in as far as possible and pull it over the primary clutch ...just a little muscle.........i still laugh when i think of the car .....hahaha

You can take it off without the tool
Just get the belt onto the edge of the secondary and roll it off by turning the clutch (and the track) It can be done. Did it on my 670 like that all the time.

Well I got it off.I used a tap,thought maybe I could fix the threads just enough to get the clutch open one last time.I was screwing the tap in and the clutch started to open and I thought great I'll just screw it in until I can get the belt off.took the belt off and backed out the tap and the end of the tap is broke off in the clutch :cussing: I'm hoping if I relieve the pressure on the tap by spreading the clutch it will come out easily.If I have to disassemble the secondary how can I do it without the special tool?Remember I'm working alone here.I've done it before with a couple of extra hands holding and pushing but I don't have that luxury this time.

use the car, i'm telling all of you. :p

Use an allen wrench to remove one of the adjusters next to the stripped out hole. Your belt removal tool should fit in there to remove the belt.

Get a heli-coil installed in the clutch half. I haven't had a problem with it since.

I got the belt off but that sounds like an excellent idea Zog.I'll file that away for future reference.

tap the hole to 1/4-20 and use a 1/4-20 bolt and it will work just like b4

use an allen wrench and remove one of the belt adjusters then use the belt removal tool in the hole the allen screw came out of. I also ground a little off the end of the belt removal tool so more threads were engaged when the tool started to open the secondary. mine has been like this for three years with no problems since.

funny stuff, next time just pull the moveable primary sheave. it does come apart without a puller.

I would like too see someone push the secondary apart.Don't forget on a ski-doo its the inner sheave that moves,so its right next to the tunnel.The belt was up out of the clutch about a good 1/8 or more so there was no way to get a hold of the outer edge of the clutch.That leaves only the front section of the secondary open between the primary and the secondary and with the belt on theres no way your getting in there,even with one hand.I probably could have rolled it off but something has to give a little bit to do this and like I said it was a brand new belt so I really didn't want to pry it off.Anyways its off and everything is fixed up ready for the weekend.Thanks for all the reply's. :)

oldyeller: Here,s how we did it in the old days: grab the inner half and turn clockwise as much as possible. Then grasp the belt on top and pull up, it will open the driven enough to remove the belt. Dino

take it off the driven clutch first. Put some muscle into it twist and pull.

If you are putting on a new belt,.......... use a RAZOR KNIFE (or saw) and cut the old one off. Beats getting mad, cussing the sled and yelling at your wife and kids!

What's all the fuss about?

Turn the inside sheave clockwise, and spread the sheaves by pushing down on the belt. Once it's about 1/2 inch below the top edge, turn the clutch to remove the belt.

If you do it with the car, be sure to catch it for "america's funiest video"