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Clutch puller issues. Which one?
started by bigbadjim
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December 10th 2008 at 5:05 PM
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bigbadjim
Junior Member
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384 Posts 
Group: Members
Member Since: October 27th 2004
Location: White City, Saskatchewan, Canada
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What Primary clutch puller do I use for a 2006 Polaris 900 switchback? I just bent the end of mine all to crap. This is the first time using it so I thought maybe I'm using the wrong one. I used a large breaker bar with my SLP clutch holding tool and no luck. Tried packing it full of grease with no luck either. Then I tried leaving the puller on and using a heat gun on the clutch shaft and still nothing? Tapped the end a bit with a hammer and notta.... Am I using the wrong tool or what? Pulled the puller out and the end is all twisted and bent.
What part number and brand do you use?
I'm using the Sno-stuff 725-207
White City, Saskatchewan, Canada
06' Polaris switchback, 900, 144"/1.75" track, e/start, reverse, timbersled air intake, slydog hot air vents, MBRP can, supersonic blue. (mine)
08' Polaris Dragon FSTurbo, custom long track, 1.75" track, 21/40 gears, red (wifes)
73' Skiroule RTX 447, minty original, 440 sachs f/c (Sons)
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December 10th 2008 at 8:16 PM
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CanadianXCR
New Ice Ripper!
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1642 Posts 
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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The brand you're using is a problem.  Get a better quality puller, you'll pay more but get more. Cheap pullers don't have a very long life especially if the clutch is hard to come off initially. I find if it's really stubborn I'll leave it overnight and sometimes it'll be popped off in the morning or give a little tap or another crank and it's off. Use a very thin coat of anti-seize to make it easy to remove in the future, I've also been told to use some chalk or talcum powder.
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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December 10th 2008 at 11:41 PM
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ZRT600
Senior Member
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2914 Posts 
Group: Members
Member Since: November 19th 2002
Location: Sudbury, Ontario, Canada
Current Sled: 09 X-Fire 800 SnoPro
2008-2009 Miles: 610
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I know somebody is going to tell me I'm wrong here, but here is what works for me, put grease on the threads of the puller, this will help avoid stripping it, use an impact, I use an IR 2135TI 1/2" impact. If that hasn't stripped mine I can't see any normal impact doing any damage.
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December 11th 2008 at 6:51 AM
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FUSION900PA
Average Member
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942 Posts 
Group: Members
Member Since: October 20th 2005
Location: Edinburg, PA, USA
Current Sled: SNOW CHECK 09 D8 SP
2008-2009 Miles: 1100
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You never should use an impact wrench....
"If you ain't first, you're last" Ricky Bobby
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December 11th 2008 at 8:29 AM
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arcticcatmatt
Spleen Splitter
arcticcatmatt leaving after work for 3 days of shotgun season back home!
Updated Yesterday at 12:16 PM
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14007 Posts 
Group: Moderators
Member Since: November 25th 2001
Location: Berkshire, NY, USA
Current Sled: 96/97 ZRT 600
2008-2009 Miles: 450
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Sno-stuff = suck stuff
From my readings all these years online, it seems that the best ones are EPI's. They are not made in china and they are hardened. Of course, they are more money. My dealer had the junk parts unlimited ones for 20 bucks, or the good EPI's for 40. I got the EPI. My clutch was a pain to get off but that baby did it.
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December 11th 2008 at 1:04 PM
[ Modified December 11th 2008 at 1:10 PM
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shortstop20
I NEED SNOW!!!!
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3836 Posts
Group: Members
Member Since: August 9th 2004
Location: Stickney, SD, USA
Current Sled: '09 Summit XP 800R 154" X
2008-2009 Miles: 400
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Sno-Stuff = JUNK I wouldn't go near my sled with one of their pullers or most of their stuff for that matter. This is one place where you absolutely don't want to skimp on quality and you do get what you pay for. Buy the high quality EPI puller and be done with it. Just imagine how pissed you'd be if you broke the puller off INSIDE the clutch, it has happened with junk pullers like Sno-Stuff. Throw it on the bench and use it as a chisel from now on.  Just an FYI for everybody else, Parts Unlimited puller = JUNK as well. STAY AWAY FROM THEM. I've pulled my clutch off with my EPI puller probably 20 times and it still looks brand new. It's been banged around, dropped, hit with a hammer, still straight as an arrow, not stretched at all and the threads are perfect. Definitely a high quality piece. Never used their economy puller, I'd go for the high quality version.
2009 Ski-Doo Summit XP 800 154" X package - Quick Clickers, Between the Lines Designs Ice Scratchers, Tunnel & Rail Stiffeners
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December 11th 2008 at 3:00 PM
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bigbadjim
Junior Member
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384 Posts
Group: Members
Member Since: October 27th 2004
Location: White City, Saskatchewan, Canada
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Thanks for all the great replies! Still haven't got it off though.
White City, Saskatchewan, Canada
06' Polaris switchback, 900, 144"/1.75" track, e/start, reverse, timbersled air intake, slydog hot air vents, MBRP can, supersonic blue. (mine)
08' Polaris Dragon FSTurbo, custom long track, 1.75" track, 21/40 gears, red (wifes)
73' Skiroule RTX 447, minty original, 440 sachs f/c (Sons)
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December 11th 2008 at 3:49 PM
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shortstop20
I NEED SNOW!!!!
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3836 Posts
Group: Members
Member Since: August 9th 2004
Location: Stickney, SD, USA
Current Sled: '09 Summit XP 800R 154" X
2008-2009 Miles: 400
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I honestly don't think you'll be able to until you get a good puller.
2009 Ski-Doo Summit XP 800 154" X package - Quick Clickers, Between the Lines Designs Ice Scratchers, Tunnel & Rail Stiffeners
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December 11th 2008 at 8:08 PM
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bigbadjim
Junior Member
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384 Posts
Group: Members
Member Since: October 27th 2004
Location: White City, Saskatchewan, Canada
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Well, we tried my new puller and a friends EPI puller tonight and bent both of them too! Tried heating it with a propane torch and f*%# all happened.
I booked it into the Polaris dealer for monday. They were the dumb a$$e$ that put it on last march when it was in for service. Obviously they put it on dry as a fart and probably torqued the crap out of the bolt with a strong impact!
I'll let you guys know how it turned out!
White City, Saskatchewan, Canada
06' Polaris switchback, 900, 144"/1.75" track, e/start, reverse, timbersled air intake, slydog hot air vents, MBRP can, supersonic blue. (mine)
08' Polaris Dragon FSTurbo, custom long track, 1.75" track, 21/40 gears, red (wifes)
73' Skiroule RTX 447, minty original, 440 sachs f/c (Sons)
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December 11th 2008 at 11:29 PM
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toomany
Starting Member
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45 Posts
Group: Members
Member Since: November 11th 2008
Location: Auburn, Mi, USA
Current Sled: '05 700 XcSp
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Quote originally posted by shortstop20 I've pulled my clutch off with my EPI puller probably 20 times and it still looks brand new. It's been banged around, dropped, hit with a hammer, still straight as an arrow, not stretched at all and the threads are perfect. Definitely a high quality piece. Never used their economy puller, I'd go for the high quality version.
That makes me feel good, I just ordered an EPI puller for my sled. 
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December 12th 2008 at 6:03 AM
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shortstop20
I NEED SNOW!!!!
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3836 Posts
Group: Members
Member Since: August 9th 2004
Location: Stickney, SD, USA
Current Sled: '09 Summit XP 800R 154" X
2008-2009 Miles: 400
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Who's to say if his was the high quality or economy version though?
2009 Ski-Doo Summit XP 800 154" X package - Quick Clickers, Between the Lines Designs Ice Scratchers, Tunnel & Rail Stiffeners
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December 19th 2008 at 10:17 AM
[ Modified December 19th 2008 at 10:18 AM
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bigbadjim
Junior Member
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384 Posts
Group: Members
Member Since: October 27th 2004
Location: White City, Saskatchewan, Canada
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Well, the 900 has been at the Polaris Dealer for a whole week now. They called me today and said they can't get the clutch off either! They bent a puller and even tried a torch with still no luck.
The whole reason behind the removal of the clucth is because the belt blew into pieces and some fragments got between the bushing and shaft and jambed the clutch up on me. The clutch flew in, grabbed the belt and stayed there.
There saying maybe we have to cut it off! 
White City, Saskatchewan, Canada
06' Polaris switchback, 900, 144"/1.75" track, e/start, reverse, timbersled air intake, slydog hot air vents, MBRP can, supersonic blue. (mine)
08' Polaris Dragon FSTurbo, custom long track, 1.75" track, 21/40 gears, red (wifes)
73' Skiroule RTX 447, minty original, 440 sachs f/c (Sons)
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December 19th 2008 at 10:21 AM
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put the puller in, get it tight, hammer the end of the puller with an air chisel with blunt tip, then tighten a little more, let the air hammer try to vibrate off the clutch. heat is the last thing i would try.
nothing goes like 3 holes!!
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December 19th 2008 at 10:46 AM
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Garceau
Advanced Member
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1044 Posts
Group: Members
Member Since: October 23rd 2005
Location: Mauston, WI
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Did you tell the dealer they were the ones that put it on? they will probably try and blame you anyways saying you took it off and installed it wrong.
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December 19th 2008 at 1:15 PM
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bigbadjim
Junior Member
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384 Posts
Group: Members
Member Since: October 27th 2004
Location: White City, Saskatchewan, Canada
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The clutch Finally came off! But its junk. They took the heat to it and it came off with a extreme bang. The fixed sheave is all warped to crap. And the inner bushing is all chewed to crap. Looks like it was warped for a while. The shaft chewed into the bushing pretty good, no wonder why it got stuck engaged.
Could the clutch be warped from all the heat from the belts? I don't have any vent kits, and still have the stock airbox.
White City, Saskatchewan, Canada
06' Polaris switchback, 900, 144"/1.75" track, e/start, reverse, timbersled air intake, slydog hot air vents, MBRP can, supersonic blue. (mine)
08' Polaris Dragon FSTurbo, custom long track, 1.75" track, 21/40 gears, red (wifes)
73' Skiroule RTX 447, minty original, 440 sachs f/c (Sons)
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