Well looking closer at my primary clutch (clutch on engine) on my 1999 700SKS I have a broken spring in the clutch. Looking towards the inside of the clutch I can see 2 spring ends, which I am assuming means the spring has broken.

So how do I remove my primary clutch?

I have removed the bolt on the outside end of the clutch but it doesn't want to come off. I thought before I try hitting it very hard I should ask. Is there something else I need to remove or loosen before the clutch will come off?

Do Not hit your clutch with any instrument of mass destruction. You must have a clutch puller to properly remove your primary clutch. One may purchase a clutch puller from your friendly Polaris dealer, EPI, Dennis Kirk, Shadetree and others for $25 to $35, get one specific to your engine and year. Explain why you think your spring is broken again, maybe you can replace it with out pulling the clutch.

you can repalce a clutch spring with out pulling the clutch???????????????

Yes indeed you can. Take the cover off with the clutch attached to the motor.

Northern700sks, everyone should have a clutch puller in their toolbox. There is no way to get the clutch off without one. A good hint when removing your clutch is to load up the bolt hole with grease before inserting the clutch remover. Will make the clutch pop off with ease.

Inside the clutch there is a large spring, blue I believe, and when I was inspecting it I could see the inside, or side closest to the engine, spring end and then I noticed two spring ends on that side. Therefore I believe the spring in broken in two pieces, close to the inside.

The problem with the sled was that the clutch system was sticking and when I let off the throttle the machine would continue to go and using the brake then caused the machine to stick.

How complicated is changing a spring in the clutch?

My Polaris dealer closed last spring and I live in an isolated community with only a Ski-Doo dealer. The nearest Polaris dealer is 200 miles away.

Blaine




quote=NewfieBullet,Nov 30 2004, 08:35 AM]
Yes indeed you can. Take the cover off with the clutch attached to the motor.

Northern700sks, everyone should have a clutch puller in their toolbox. There is no way to get the clutch off without one. A good hint when removing your clutch is to load up the bolt hole with grease before inserting the clutch remover. Will make the clutch pop off with ease.
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If the spring is broken, it should be really easy to pull the clutch cover off. Unbolt the 6 retaining bolts and there you are. You may need a second pair of hands to compress the spring a bit to start the bolts back on. The clutch is balanced. You have to replace the cover in the same position as it came off. There should be some X's marked on the cover and on the sheaves and spider to help you align. If not, mark both with a marker so it goes back the same way it comes off. I put a little loctite (medium strength) on the bolts and torque to 90 inch/lbs. (that's not a lot of torque, you do NOT want to overtorque and strip out a bolt hole).

Somehow this sounds too easy, sorta like watch the car builder shows rebuild a car on TV in an hour!

So I will be able to insert the new spring and be able to compress it enough to get the bolts started?

I know how it feels when you only have 1 dealership to rely on...

try to find a friend that is familiar with clutches.

if he can help you it might only cost you a spring plus the number of beers he drinks while fixing it

YES!!! you can change the spring without removing the clutch from the crank, just back out the six cover bolts evenly, then as someone mentioned on a previous post you might want to have a second persons hands to help push the cover on evenly until you get all six of the cover bolts started, snug them down and then torque to the aforementioned spec, and be "CAREFUL" not to over tighten, this could cuase the threads in a hole to become stripped out, or worst case scenario a broken bolt, been there done that, not a fun fix. Aso as mentioned above, make sure all 3 X's are lined up with eachother, Polaris primary clutch's are balanced as a complete unit, if these X's are not stacked over each other the clutch will be out of balance and I would think that crankshaft failure would happen soon afterwards if run that way.....

Thanks everyone, I know what I am going to try tonight.

Hopefully I can get a spring shipped in from a Polaris dealer.

THANK YOU, 6 bolts later and I have a broken spring sitting on the bench.

Now I just hope it goes back in!

So am I best off buying a spring from a Polaris dealer or are clutch springs common?

Polaris dealer is the simplest. Or you could order a clutch kit that includes a spring.

When removing the cover with clutch on sled, put a large washer on the center bolt and reinstall in clutch, when you remove the 6 cover bolts the washer will hold the cover then back off the large bolt . then when spring is changed use large bolt with washer to tighen cover in to be able to start the 6 cover bolts. No need of more hands trying to compress spring to start cover bolts.

Originally posted by RMKmod@Dec 14 2004, 10:49 PM
When removing the cover with clutch on sled, put a large washer on the center bolt and reinstall in clutch, when you remove the 6 cover bolts the washer will hold the cover then back off the large bolt . then when spring is changed use large bolt with washer to tighen cover in to be able to start the 6 cover bolts. No need of more hands trying to compress spring to start cover bolts.
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Very Good Idea!