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SECONDARY REMOVAL II
- removal tool worked great
started by EarnhardtNorth
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October 30th 2009 at 7:09 PM
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EarnhardtNorth
Junior Member
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167 Posts 
Group: Members
Member Since: June 13th 2007
Location: Ontario, Canada
Current Sled: 1995 STORM
2008-2009 Miles: at a time
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I had started a post way back in May about an incredibly stuck secondary clutch on a 91 RXL. I built a puller for this and it worked really well. Just thought I'd pass along some pics of it.
 Puller 2  Puller 3  Puller 1
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Site Supporter
Group: Site Supporters
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October 30th 2009 at 7:23 PM
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bm_zimmer
Starting Member
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9 Posts
Group: Members
Member Since: October 15th 2009
Location: syracuse, ny, USA
Current Sled: 96' xcr 60 sp
2008-2009 Miles: 800
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very good sir! looks like it worked well.
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October 30th 2009 at 7:34 PM
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EarnhardtNorth
Junior Member
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167 Posts
Group: Members
Member Since: June 13th 2007
Location: Ontario, Canada
Current Sled: 1995 STORM
2008-2009 Miles: at a time
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Thanks, Yeah it worked perfectly. I beat, banged, heated, soaked, cursed, swore and nothing seamed to budge it. I've never seen a secondary so difficult to get off!
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October 30th 2009 at 7:52 PM
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scumpman
temporarily out of order
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690 Posts 
Group: Members
Member Since: October 12th 2004
Location: FAIRBANKS, AK, USA
Current Sled: '03 Indy 500
2008-2009 Miles: bout 800
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Was this something you came up with on your own or is there a secondary clutch removal tool outthere?? just curious..
How did your jackshaft look after you pulled that secondary?? was it a splined or keyed shaft??
'03 Indy 500 sks (Scumpman's Kicka** Snowmachine) extended skid/track to 136" from TracksUSA, AC roller clutch, Holtzman Tempaflow, clutched and geared, 2" risers, skidplate, old Pol rack.
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October 30th 2009 at 7:58 PM
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EarnhardtNorth
Junior Member
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167 Posts
Group: Members
Member Since: June 13th 2007
Location: Ontario, Canada
Current Sled: 1995 STORM
2008-2009 Miles: at a time
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It is keyed on the RXL's. I think only the smaller hp sleds got the splined shaft? The shaft cleaned up nice and now it comes on and off the way it should. I don't know of a toll you can buy for this, there really shouldn't be a need for it! This sled just never saw and preventative maintenance, until it met me! To answer your question, I designed and built it.
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October 30th 2009 at 8:28 PM
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stormrider62033
wally
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4729 Posts 
Group: Members
Member Since: December 25th 2004
Location: Gillespie, IL, USA
Current Sled: 99xcr 800
2008-2009 Miles: 500
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good post for me it was a 8 pound sledge and a piece of oak
mid Il alway's waiting for snow,moving north(way north)2001 thundercat 99xcr 800 97SPX ULTRA 96 zrt 600&800,92 doo plusX 92 v max 4 750
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October 31st 2009 at 6:52 PM
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PolarisEdge
Polaris Tech
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1180 Posts 
Group: Members
Member Since: November 13th 2005
Location: Miramichi, New Brunswick, Canada
Current Sled: '05 IQ 900
2008-2009 Miles: 1320
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Quote originally posted by EarnhardtNorth
It is keyed on the RXL's. I think only the smaller hp sleds got the splined shaft? The shaft cleaned up nice and now it comes on and off the way it should. I don't know of a toll you can buy for this, there really shouldn't be a need for it! This sled just never saw and preventative maintenance, until it met me! To answer your question, I designed and built it.
Actually big HP sleds and the newer sleds got the splined jackshafts... All the IQ's are splined I believe except maybe for the 550.
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November 1st 2009 at 7:45 AM
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Dman
Average Member
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528 Posts
Group: Members
Member Since: February 13th 2004
Location: Shell Lake, WI
Current Sled: 98 XC600's (2)
2008-2009 Miles: 150
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For me it was a sawzall and an ebay secondary for $20.
D
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November 1st 2009 at 8:35 AM
[ Modified November 1st 2009 at 8:36 AM
]
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Ugly_old_Poo_kid
techno-bumpkin
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1079 Posts
Group: Members
Member Since: March 18th 2007
Location: Walworth, NY, USA
Current Sled: 05 Edge & Frankenstorm II
2008-2009 Miles: 165
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Quote originally posted by Dman For me it was a sawzall and an ebay secondary for $20. D That doesn't leave any room for if's does it... lol Quote originally posted by EarnhardtNorth I had started a post way back in May about an incredibly stuck secondary clutch on a 91 RXL. I built a puller for this and it worked really well. Just thought I'd pass along some pics of it. Puller 2 Puller 3 Puller 1 How much does that thing weigh?
95 - Storm 800 - Modded - AKA: FrankenStorm - Totalled near 100mph at Tug Hill!
96 - XLT/SP with Storm 800 trip/trip and now EFI - FrankenStorm II lives...
95 - RXL -- Sale Pending --
05 - Edge 800 long track - Stayin' stock for now..
---------------------------------------------
It made me more compassionate, more empathetic, more nurturing...
I FEEL LIKE I'M TRAPPED IN MY OWN WORST NIGHTMARE!!!
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November 1st 2009 at 6:53 PM
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EarnhardtNorth
Junior Member
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167 Posts
Group: Members
Member Since: June 13th 2007
Location: Ontario, Canada
Current Sled: 1995 STORM
2008-2009 Miles: at a time
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I don't know? It's heavy enough to not flex while pulling, maybe 20-25lbs? It's hanging right now with paint on it or I'd throw it on the fish scale for you.
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November 1st 2009 at 7:33 PM
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Dumz1
Junior Member
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197 Posts
Group: Members
Member Since: January 21st 2009
Location: Holmen, Wi
Current Sled: 1997 XC 600
2008-2009 Miles: 850 +/-
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I was just thinking about making one of these.. got a secondary that's being a pain..
1997 XC 600
2004 Sportsman 500HO
Parting out 1993 XLT and 1997 XCR 600
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November 1st 2009 at 7:51 PM
[ Modified November 1st 2009 at 7:52 PM
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scumpman
temporarily out of order
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690 Posts
Group: Members
Member Since: October 12th 2004
Location: FAIRBANKS, AK, USA
Current Sled: '03 Indy 500
2008-2009 Miles: bout 800
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Just an observation, GREASE YOUR JACKSHAFTS.. just like EarnhardtNorth says, basic maintenance.. I learned to do it after trying to remove a stuck secondary once, never again, always grease my shaft each season  .
'03 Indy 500 sks (Scumpman's Kicka** Snowmachine) extended skid/track to 136" from TracksUSA, AC roller clutch, Holtzman Tempaflow, clutched and geared, 2" risers, skidplate, old Pol rack.
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November 1st 2009 at 8:46 PM
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Dumz1
Junior Member
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197 Posts
Group: Members
Member Since: January 21st 2009
Location: Holmen, Wi
Current Sled: 1997 XC 600
2008-2009 Miles: 850 +/-
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yup having problem with parts sled I picked up cheap.. the last two I got have been stuck on.. last one I wrecked pounding it off.. this one I'd like to save.. so thinking I best build a custom puller.
1997 XC 600
2004 Sportsman 500HO
Parting out 1993 XLT and 1997 XCR 600
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