Driven clutch was seperated, one half still on motor. The slide side had new ramps and springs installed as well as the bushing that gets pressed in. Now it will not go back on the shaft, the dealer did say that this is sometimes difficult to install. Anyone know the trick to getting the clutch back together without damaging the bushing. Thanks, 97 mxz670

I had the same problem on my 1993 Mach-1.

My cure hurts! ALOT!!

I put the stationary pulley on a piece of carpet. I held it as best I could with my feet and TWIST, TWIST, TWIST`ed with both hands the moving sheave onto the shaft. Little by little I saw small crumbs fall off the new bushing. Its not fun! I had no choice, what else are you going to do? Drill it? I kept going until I had 2 blisters on one hand. I changed hands and kept going. 1/2 an hour later, I got it on the shaft. Pull it off during twisting from time to time to clean out the bushing crumbs. Once it was finally on the shaft, I gave the moving sheave a few knocks with a rubber mallat in a criss cross pattern. This will help to set the bushing into its new home. After a few taps it finally started to move freely on the shaft. Its NO fun but it worked for me.

I dont know if this is from bad pulley prep or bad bushing tolerences from Ski Doo? I wanted to give up and bring it to a machinist for boring. Its working fine but I still have a scar on my hand from one of the blisters :cussing:

Your dealer screwed up installing the bushing. There is a specific tool and method used to get the bushing pressed in and flared out at the ends, if it's not done right you get the result you are talking about. Take it back and have them do it again.

since you had the spring out flip the half over and check that the bottom cup the spring sits in is centre to the opening for the splined end to slide thru.i've had this happen to me when changing primary springs,just give it a tap to center it.hope this will help