Posted by Bret4207 on February 09, 2021 at 10:27:17 from (207.42.20.149):
Sorry for getting waaaaay OT here guys, but I've contacted people who should know but never get back to me and scoured the internet and You Tube, and I bought and downloaded a shop manual, all to no avail!
My youngest boy bought an old Polaris Star snowmobile, an '85 model I think. The jackshaft (track drive shaft) bearings were bad, real bad. We could not get the secondary (or "driven" if you prefer) clutch off no matter what we did. Ended up cutting the shaft under the machine with a sawzall and we had to use a 20 ton press to get the secondary clutch off the shaft. Got the shaft welded back together fine and straightened it between lathe centers. I have another secondary clutch enroute because the original broke during removal, it was extremely tight on the shaft. I also got what is supposed to be the correct bearing kit which the bearings for the brake side fit fine. Problem is the other end of the jackshaft where the clutch fits is running about .997/.998 and the bearing was .016 or .017 thousandths smaller than that, which lines up with the bearing being 25MM (.984) as indicated. Everything I can find seems to indicate that the secondary clutch should be a snug, sliding fit on the shaft and onto it's key. But I can't find anything that spells that out in plain language. The interior of the old clutch is rough and hard to get an accurate read on, but is right around 1". I'm at loss at this point. Does anyone know for sure if that secondary clutch should be a "no puller required" type snug sliding fit as I think, or am I out in left field? There is nothing on the secondary clutch to give the impression it could ever have a puller attached- no holes, slots or threaded bores. I just don't know at this point.
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