Hi Guys. New to the site!
I have a 2001 D&D Racing ZR800 and my clutch started sticking and now it's stuck. I took it off, removed the spring and it doesnt move freely without tapping it. When I cleaned it, alot of junk was on the shaft, but the shaft looks in perfect shape and the weights move fine and look good. What can I do from here? I'm stuck. Do I need a special tool to take it apart more? I think I totally need to take it down and finish cleaning the shaft and make sure the bushing is ok.
Thanks!

We just went throuhg this with my buddies sled. His was locked solid. It just took alot of banging, and cleaning. We used PB Blaster and Carb cleaner and Acetone. The PB Blaster really helped. Just be sure to clean it all off before you use it, they say that stuff isn;t good for it. But anyway, spray it down and let it sit if need be, you just have to work it really good. You know I was thinking about putting it back together and spinng it on the motor, not sure if that would have helped or not.

Now I had this same experience years ago, when I first started sledding. I had (still have it) a 83 V-max 540. I bought a Comet 108EXP clutch to replace the cracked one. I used the sled one time about 100 miles. I was moving the sled around the yard and it engaged and would not disengage. It was like brand new, so I din;t want to mess it up. I sent it in and they sent it back fixed, no questions/paperwork (warranty).

So if it was me I would bust it free (use a piece of wood to bang it on) until it popped free or broke. Because I could see teraing it apart turning into a nightmare, for me anyway. I tend to be to anal about stuff and would change everything, and I would have to do it myslef, meaning I would have to make/buy the tools needed. I would end up spednign more money and time than a new clutch would be worth.

Maybee someon els has some better advice, but mine is spray it work it till you get it.