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I want to replace the bushings and possibly the weights on my 99 ZRT800, but the dealer doesn't have a puller to sell me.  Are there any tricks to doing the work without removing the clutch?

Thanks!
Scott nadeau
Concord, NH
 

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Yes you can, I know there are companies that make a tool, I think black magic offers one. You just pry the hub back and lock on one of the sheaves. Takes all the pressure off the weights.
 

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 all you need is a 3 1/2 inch long piece of 1/8 inch by 1 inch wide flat iron. Take it to your vise and bent each end 90 degress both the same way. it will look like this.  (  [   )   leave about 1/2 to 3/4 inch flange on each end. remove belt. take pry bar behind spider and pry clutch closed. Slip the new tool over the pulley. this will hold the pulley close and you can remove the weights. Make sure you put the tool on correct and that it is tight. also that it is not over top of the weight bolts.
now you can service the cams and bushings.
Caution.!!!! do not knock the tool out of place while working on the weights.  Your fingers will go missing very fast.
Taz800

  
 
 
 
 

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I have changed weights on the lake, all you need is a socket
approx. 15mm. pry the clutch to close it and put the socket in place so that it is between the spider and the outter sheave. make sure the socket is in there good and do your work.Like tazz said becareful you are working with one heck of a mouse trap.
 

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The quick clutch tool from B/M works good. Feels safer than jamming something into the spider and sheave. I need my little fingers. You can easily make a tool like this if you have the resources. better than paying for it
 

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Well, you can go to a cat dealer and ask for part #0644-245 and that should do it or Black Magic part #70-1224.

   -Auggie-
 

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hEY ZRT600MNTCAT
How do you change the weights without any special tools.
I use a clutch compressor(prybar type)and a U shaped clamp to hold the clutch shut other wise there is noway to get the weights out as the roller is to close to them.
 

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I have done this many times without missing any fingers. What I do is remove all the bolts that hold the cover on but two that are aposed to each other, then remove the last two equally as to take off the sping tention. Now you can get at everything. It takes a little longer but is safer.
 

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Just like KSZRT said.

Take the belt off, then take the cover bolts and cover off, the spring comes with.

Then you can remove the weights without any problems at all.

Why mess around when it is only a couple of bolts.


I do it all of the time, it only takes about 20 minutes for the whole job.
 

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If you have the tools (about 20.00 worth) it only takes about 5 min to change them and I have never lost a finger or had the clamp slip as long as you buy the clamp with the kit or make one that is strong enough not to bend.Also this make weight changes easier on the trail if you like to run spot on clutching.and there is no worry about damaging the soft cover bushing when taking the cover off repeatedly.I have seen more bushings destroyed by doing it that way.
 
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