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Discussion Starter #1
On my 1997 ZR 440 Ive noticed that the driven (secondary) clutch is seized on the jackshaft tight. I tried soaking the thing with penatrating oil over the summer then beating the thing off with a mallet but no sucess. I then tried making a homemade clutch puller to take it off but I couldnt get the thing off. Does anyone know a trick to gettin these SOBs off when they're seized or should I just pull the whole jackshaft out with the clutch on and get it off with a hydrolic press? My dad's 98 ZR 500's clutch also seized like that but the shop was able to get it off with a hammer.
 

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I had a freiend that had the same problem...he ended up taking apart what he could of the clutch and then heated up the outer shaft with a small torch...he also applied some rust free lub and tapped the shaft while heating it. You might need a helping hand..I get into habit taking my clutches off during the off season and spraying the shafts, both of them.
 

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Yes, the special puller, if you can get it in there :wacko:

It bolts to the 3 posts and pushes the center...you know...
 

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Discussion Starter #4
I think I might give your heating it up method a try greenskin. I hear that Arctic Cat does have a puller for this clutch because I guess the secondary sticking was quite common on the 97-98 models, Ill have to try to locate one to try it out. My dad and I made a custom puller for the clutch but the thing broke when we tried it! Anyone know why these seize in the first place? bad reactions between the two different metals or something?
 

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i had one that was seized so hard that i had to pull the whole jackshaft assembly out and put it in the press. :eek:
 

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Discussion Starter #6
Ya Im thinking about taking the jackshaft out on mine and putting it into the press
 
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You can try inserting grease a little at a time and if you can some how put a clutch puller on the jackshaft then start turning it shoud pop off if it does not put a little more grease in and do the same thing,I know that this trick works on your primary clutch if that happens so maby it will work in this case .good luck
 

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The AC puller for the secondary does not seal tight like the drive clutch puller. If you try the grease method...have a lot of grease and even more rags, cause you will have a large mess! If the secondary shaft is not kept lubricated over the years it doesn't matter what year sled you have, you WILL have problems. Be careful with the heat, so you don't damage the bearing too.
 

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Discussion Starter #10
Yeah after we got the clutch unseized on the 98 ZR 500 we load that thing up with never seize just before the start of every season just incase ^_^
 

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Pull the jackshaft and use the never seize, which should be done every year on all Cat secondarys.
 

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you can buy the puller at rv motor sports for the secondary, also one way i took mine off is to take the bolt out and spacer and spray wd-40 and install the bolt and ride it hard across the lake a couple times it will loosen up and come off easer with a light tapping with a rubber hammer.
 
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