I want to remove the outer primary clutch sheeve to clean the clutch, but I can only slide it so far on the shaft and it hits the lower cowl. It doesn't give me enough room to slip it off. I tried bending the cowl by wedging some long boards in there, but still not enough room. Any ideas how to get this off without having to remove the inner sheeve and needing a clutch puller? Heating up the cowl so it's more pliable possibly? Need about 1 more inch.

I had the same problem on my old 92 Mach 1. What I did was take out all (i think there were 3) the bolts that hold the top part of the cowl to the bracing. Then I removed the govenover cup from the clutch before the front sliding half would come off. The govenor cup comes off very easily. Hope this helps.

Steve

Ya theres usually some bolts that hold the belly pan to the metal part of the chassis where your foot goes in.If you remove these it will allow you to bend the flexible belly pan out far enough to get it out.I really wouldn't try heating it. :doh:

Really cant do it on F and S chassis sleds, gotta pull the whole clutch. The ck3 and zx sleds allow you to pul it out thru the hole in the side of the belly pan.

Go buy the puller. You are going to need to clean the clutch again and pulling it is no big deal.

Clutch Puller and Button Retainer Clips: $30.99 (US)

Spanner Wrench to hold Primary: $19.99 (US)

Time: 15-30 Seconds

Saving your Sanity: PRICELESS!


Just buy the tools. What is $50 in the snowmobile world? Remember, the two halves of the clutch are indexed for balancing, so make sure you put them back the same way. If you are going to remove the primary spring, you will also need a spring retaining tool. Basically a steel plate with a 1/2" threaded rod welded to it, with a big washer and giant wing nut to hold spring pressure without taking your head off. Make it yourself or about $40 from the store. Dennis Kirk sells them all and you can have it in two days.