I'm having a hell of a time removing the primary clutch on a 96 Arctic Cat 580 ext. The 13mm bolt that holds it to the shaft turns out as far as the threads push it, then stops. I've tried to grab it with needle nose pliers and pull it out, but it won't come. Any ideas? I've got some bad crank bearings to replace but I'm dead in the water right now...

If I am understadnign you right it sounds liek the threads on the insdie fo the crankshafts might be a little messed up, no real big deal though. Try taking an adjustable wrench, and close it around the bolt, just under the head, then while pulling out on it, spin the bolt (air wrench will work good here), you may really have to pull hard. When you do get it out, just runa tap down the crank and hopefully you still have some good threads in there (which it sounds like you do because the bolt does start to come out.

Originally posted by jj_ream@Nov 23 2004, 12:06 PM
I'm having a hell of a time removing the primary clutch on a 96 Arctic Cat 580 ext.* The 13mm bolt that holds it to the shaft turns out as far as the threads push it, then stops.* I've tried to grab it with needle nose pliers and pull it out, but it won't come.* Any ideas?* I've got some bad crank bearings to replace but I'm dead in the water right now...
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Isn't there a spacer in there on that year clutch? I think that may be what is holding you up possibly. You may just have to try what is mentioned above. Just keep working at it. Maybe try spraying some lube in there too.

The bolt is still recessed within the clutch by about 1/4-inch. Tightened in the whole way it's about 1-inch in there. I'm thinking of taking a screwdriver and putting just a little lip at the end to hopefully grab the underside of the bolt while turning it out. I did try to pull it out with needlenose pliers but they just keep slipping, and needlenose visegrips are too thick to fit in there. I guess I'll just keep at it. I may have to drill it and tap it to thread a bolt into the bolt!Not like I had anything else to do :bash:

Originally posted by jj_ream@Nov 23 2004, 04:15 PM
The bolt is still recessed within the clutch by about 1/4-inch.* Tightened in the whole way it's about 1-inch in there.* I'm thinking of taking a screwdriver and putting just a little lip at the end to hopefully grab the underside of the bolt while turning it out.* I did try to pull it out with needlenose pliers but they just keep slipping, and needlenose visegrips are too thick to fit in there.* I guess I'll just keep at it.* I may have to drill it and tap it to thread a bolt into the bolt!Not like I had anything else to do :bash:
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Ahh, tha does suck, but no biggie. You could drill and tap that bolt into it, butyou would need to do a reverse thread (and easy out would work), or It may be asier to just weld another bolt (smaller one) to the one that is stuck, then just work it out that way.

Did you try tipping the sled on it's side and seeing if the bolt will fall out? That bolt takes a 1/2" 12 point socket, so if you were using a 13mm socket you are slightly over sized, (.3mm) to be exact, and that may be enough to not hold onto the bolt head tight enough to allow you to pull it out when it reaches the end of the treads.

There is a plastic spacer in there. Try blowing air around it. Or keep trying with needle nose. Hold on while someone else spins the clutch clockwise.

spaceman is right. the bushing can be a pain getting out. can you get ahold of the bolt head with a pair of vise grips.

oh by the way.when you go back together don't put the bushing back in. nobody does.

Originally posted by Spaceman@Nov 23 2004, 06:04 PM
There is a plastic spacer in there. Try blowing air around it. Or keep trying with needle nose. Hold on while someone else spins the clutch clockwise.
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Glad to see my memory serves me correctly.
Thanks Spaceman.

Thanks Guys, I'll keep at it.

urathane bushing is deformed because of compression, long nose vicegrips has always worked for us. The bushing is there to minimise harmonic vibration and bolt breakage. Cat changed to a different bolt in later years and elininated the bushings (one aluminum, one urathane)

A good pair of needle nose vice grips will really help. That bushing seems to get malformed and stuck on the threads of the bolt. Hope you don't lose too much from the knuckles on this.

Thanks, I'm sporting a really nice looking blood blister on my trigger finger from the 90degree needlenose that slipped off and bit melast night. The first day of buck is on monday, and I might have to shoot with my middle finger(providing I don't screw that one up too). I guess I could use a stick to pull the trigger if it gets too bad! There's probably an Arctic Cat engineer laughing at me somewhere right now.

Ever look at the job postings on Arctic's website? THey don't hire engineers.

Needle nose Vise Gripps is all you need.