How to Disassemble a Ski Doo Primary Clutch in 5 Simple Steps

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Welcome to our guide on how to disassemble a Ski Doo primary clutch in 5 simple steps. Whether you’re a seasoned rider or a beginner, learning how to disassemble a clutch is an essential skill that can save you time and money. In this article, we will take you through the process step-by-step, so you can confidently disassemble, inspect, and reassemble your Ski Doo clutch with ease.

The Ski Doo primary clutch is a crucial component of your snowmobile’s drivetrain system. The clutch engages and disengages the engine’s power to the track, making it an essential part of your sled’s performance. Therefore, it’s important to ensure that your clutch is well maintained and inspected regularly. In this guide, we’ll show you how to disassemble the clutch, inspect its components, clean them, and reassemble the clutch. By doing so, you’ll be able to keep your clutch in top condition and avoid costly repairs down the road.

But first, let’s take a closer look at the Ski Doo primary clutch and how it works. With our step-by-step guide, you’ll be able to disassemble your Ski Doo clutch like a pro in no time. So, let’s get started!

Ready to dive into the world of Ski Doo clutch maintenance? Keep reading to learn how to disassemble your clutch in just 5 easy steps.

Step 1: Removing the Primary Clutch

If you’re experiencing issues with your Ski Doo primary clutch, it may be time to disassemble it and give it a thorough cleaning. Removing the clutch is the first step in this process, and it’s essential to do it correctly to avoid any damage to your snowmobile. Before you get started, make sure you have the right tools on hand, including a wrench, puller, and a snap ring plier.

First, remove the belt from the clutch by loosening the bolt that holds the clutch onto the shaft. Then, use the puller to remove the clutch from the shaft. Next, you’ll need to remove the snap ring that’s holding the clutch together. Use the snap ring plier to carefully remove the snap ring and set it aside for later. With the snap ring removed, you can now pull the clutch apart.

It’s essential to take your time when removing the clutch to avoid damaging any of the components. Be sure to keep all the parts in a safe place and take note of their position, so you can easily reassemble the clutch later. With the clutch removed, you’re ready to move on to the next step in the process of disassembling your Ski Doo primary clutch.

1.1 Removing the Clutch Bolt

  1. Step 1: Start by removing the clutch cover and the belt from the clutch.

  2. Step 2: Use a clutch holder tool to hold the clutch in place while removing the bolt.

  3. Step 3: Use a socket wrench to remove the bolt by turning it counterclockwise.

  4. Step 4: Once the bolt is removed, carefully slide the clutch off the shaft.

  5. Step 5: Place the clutch in a secure location until you are ready to disassemble it.

Removing the clutch bolt is the first step in disassembling the Ski Doo primary clutch. It is important to follow these steps carefully to avoid damaging the clutch or any other components. Make sure to have all the necessary tools on hand and work in a clean, well-lit workspace to prevent any mishaps.

1.2 Separating the Clutch from the Engine

With the clutch bolt removed, you can now separate the clutch from the engine. The clutch is held onto the engine by a splined shaft, which requires a little bit of force to release. Use a clutch puller tool to separate the clutch from the engine.

Insert the puller tool into the clutch and thread the center bolt in. Once the bolt is tight, use a wrench to turn it counterclockwise. This will pull the clutch off of the engine. Be careful not to lose any small parts that may fall out during the process.

If the clutch does not come off easily, do not force it. Double-check to make sure that you have removed all the bolts holding the clutch onto the engine. If everything is removed, apply some heat to the clutch with a propane torch to help break any corrosion between the clutch and the engine.

Step 2: Disassembling the Clutch

Now that you have the primary clutch removed, it’s time to start disassembling it. The first step is to remove the clutch cover by unscrewing the bolts holding it in place.

Next, remove the clutch spider from the shaft by pulling it off. You may need a clutch puller tool to help with this step.

Using a socket wrench, remove the bolts holding the clutch weights in place. Be sure to keep track of the location and weight of each bolt as you remove them.

After removing the bolts, gently lift out the clutch weights and set them aside. Then, remove the spacer and spring from the shaft.

The final step in disassembling the clutch is to remove the clutch sheave by pulling it off the shaft. You may need to use a puller tool for this step as well.

2.1 Removing the Clutch Cover

Before you can disassemble the clutch, you’ll need to remove the clutch cover. Use a socket wrench to remove the bolts that secure the clutch cover to the engine. Depending on the model of your Ski Doo, there may be anywhere from four to eight bolts to remove. Keep the bolts in a safe place so you don’t lose them.

Once you’ve removed the bolts, gently pry the clutch cover away from the engine. Be careful not to damage the gasket that seals the cover to the engine. If the gasket becomes damaged, you’ll need to replace it before reassembling the clutch.

With the clutch cover removed, you’ll have a clear view of the primary clutch assembly. You’re now ready to start disassembling the clutch so you can inspect and clean its components.

Step 3: Inspecting the Clutch Components

Once you have disassembled the Ski Doo primary clutch, it’s time to inspect all of the components. Start by examining the bushing in the center of the clutch. Look for any signs of wear or damage, and make sure that it moves freely.

Next, inspect the weights and rollers. Check for any cracks, chips, or excessive wear. If you find any problems, these parts will need to be replaced.

Inspect the helix and spring for any signs of damage or wear. If the helix is warped or the spring is worn out, they will need to be replaced. Also, check the spider and cam arm for any signs of wear or damage.

Finally, inspect the clutch housing for any cracks, chips, or damage. If you find any problems, the housing will need to be replaced. Once you have inspected all of the components, you can move on to cleaning them.

Note: It is important to inspect all of the components thoroughly to ensure that your Ski Doo primary clutch is working properly. Any damaged or worn parts should be replaced before reassembly.

3.1 Inspecting the Clutch Sheaves

Inspecting the clutch sheaves is an important step in ensuring that your Ski Doo performs optimally. Look for signs of wear or damage on the sheaves’ surfaces. If you see grooves or cracks, it’s time to replace them.

Use a micrometer to check the sheave’s diameter. If it’s outside the manufacturer’s specifications, replace the sheaves. Make sure to inspect the bushings and rollers for wear or damage as well.

If you find any issues with the sheaves or other components, make sure to replace them before reassembling the clutch. Neglecting to replace damaged or worn components can lead to poor performance and even accidents while riding.

Step 4: Cleaning the Clutch Components

Clean the clutch sheaves: Use a clutch cleaner or brake cleaner to clean the sheaves. Spray the cleaner onto a clean rag and wipe down the sheaves until they are free of any debris or residue. Be sure to clean both the drive and driven clutch sheaves.

Clean the clutch bolt: Wipe down the clutch bolt with a clean rag to remove any debris or dirt. Apply a small amount of anti-seize lubricant to the clutch bolt before reinstalling it.

Clean the clutch cover: Use a clean rag to wipe down the clutch cover, removing any debris or dirt. Inspect the clutch cover for any signs of damage or wear, such as cracks or missing pieces. If the clutch cover is damaged, it should be replaced before reinstalling the clutch.

Properly cleaning the clutch components is important to ensure they work efficiently and last longer. Skipping this step can lead to poor performance, damage, and even accidents. Don’t take shortcuts when it comes to the maintenance of your Ski Doo’s clutch.

4.1 Cleaning the Clutch Sheaves

Step 1: Use a soft-bristled brush to remove any debris or dirt from the sheaves.

Step 2: Apply a recommended cleaning solution to the sheaves, and let it sit for a few minutes to allow the solution to penetrate and loosen any remaining dirt or grime.

Step 3: Use the soft-bristled brush to scrub the sheaves thoroughly, making sure to clean all areas of the sheaves.

Step 4: Rinse the sheaves with water to remove any remaining cleaning solution and debris.

Step 5: Dry the sheaves completely using a clean, dry cloth or compressed air. Ensure that no moisture remains on the sheaves before reassembling the clutch.

4.2 Cleaning the Clutch Housing

If you’re experiencing slipping, vibrations or difficulty shifting gears, it might be time to clean your clutch housing. Before getting started, make sure you have all the necessary tools and equipment, including a socket wrench, a drain pan, brake cleaner, and a scrub brush.

The first step is to remove the transmission and clutch components from the engine block. Be sure to follow the manufacturer’s instructions carefully, as this process can vary depending on the make and model of your vehicle. Once the clutch housing is exposed, use a scraper or wire brush to remove any debris or buildup, taking care not to damage the surface of the housing.

Next, apply brake cleaner to the clutch housing, being careful not to get any on your skin or clothing. Use a scrub brush to thoroughly clean the surface, paying special attention to any areas with heavy buildup. Once you’ve removed all the dirt and grime, wipe down the clutch housing with a clean rag and allow it to air dry before reassembling the transmission and clutch components.

It’s important to clean your clutch housing regularly to prevent excessive wear and tear on your vehicle’s transmission components. By following these simple steps and using high-quality cleaning products, you can keep your clutch housing in top condition for years to come.

Debris, buildup, scrub brush
  • Remove transmission and clutch components from the engine block
  • Use a scraper or wire brush to remove debris or buildup
  • Apply brake cleaner to the clutch housing
  • Scrub the surface with a brush, paying attention to heavy buildup
  • Wipe down the clutch housing with a clean rag and air dry before reassembling

Regular maintenance of your clutch housing is essential to keep your vehicle running smoothly. Cleaning your clutch housing at least once a year will help prevent excessive wear and tear on your transmission components, saving you time and money in the long run. Remember to always follow the manufacturer’s instructions and use high-quality cleaning products for best results.

Maintenance, transmission, cleaning products
StepDescriptionTool/equipment needed
1Remove transmission and clutch componentsSocket wrench
2Remove debris or buildup from clutch housing surfaceScraper or wire brush
3Apply brake cleaner to clutch housing surfaceBrake cleaner
4Scrub clutch housing surface with a brushScrub brush
5Wipe down clutch housing with clean rag and air dryClean rag
Cleaner, surface, equipment

Step 5: Reassembling the Clutch

Now that you’ve cleaned all the parts of the clutch, it’s time to start reassembling. The first step is to install the new clutch disc onto the flywheel.

Before installing the clutch disc, make sure to properly lubricate it with some transmission fluid. This will prevent any damage to the disc during operation and also help to prolong its lifespan.

Once the clutch disc is in place, the next step is to install the pressure plate and secure it with the bolts. Make sure to torque the bolts to the manufacturer’s specifications, as overtightening or undertightening can cause issues with the clutch operation.

After the pressure plate is secured, it’s time to install the release bearing onto the fork. Make sure to properly lubricate the bearing with some high-temperature grease, as this will help to prevent any squeaking or grinding noises during clutch operation.

The final step in reassembling the clutch is to install the bellhousing and attach it to the engine block with the bolts. Make sure to torque the bolts to the manufacturer’s specifications and check for any leaks or damage to the housing.

With the clutch reassembled, it’s time to test it out. Start the engine and engage the clutch pedal to see if it operates smoothly and without any issues. If everything is working properly, you’re ready to hit the road!

5.1 Reassembling the Clutch Components

After successfully replacing the worn-out clutch components, it’s now time to reassemble the clutch. Here are the steps to follow:

Step 1: Begin by placing the new clutch disc onto the flywheel, making sure that the side marked “flywheel side” is facing towards the flywheel.

Step 2: Install the new pressure plate onto the flywheel and finger-tighten all of the bolts. It’s important to tighten the bolts in a crisscross pattern to ensure even pressure on the clutch disc.

Step 3: Torque the bolts down to the manufacturer’s specification using a torque wrench. This will ensure that the pressure plate is secured properly to the flywheel.

Alternatively, you can follow these steps:
  • Step 1: Place the clutch disc onto the flywheel with the “flywheel side” facing towards the flywheel.
  • Step 2: Install the pressure plate onto the flywheel and finger-tighten all of the bolts.
  • Step 3: Use a torque wrench to torque the bolts down to the manufacturer’s specification.
  • Step 4: Install the release bearing onto the clutch fork.
  • Step 5: Install the transmission onto the engine and tighten all of the bolts to the manufacturer’s specification.

Once you have completed these steps, the clutch assembly should be properly reassembled and ready to be used. Congratulations on successfully replacing and reassembling your clutch!

5.2 Torqueing the Clutch Bolt

After reassembling the clutch components, the next step is to torque the clutch bolt. To torque the clutch bolt, you will need a torque wrench and a socket that fits the bolt. Refer to the manufacturer’s specifications for the required torque measurement for your specific make and model.

Make sure the clutch is aligned and seated properly before torquing the bolt. This will ensure that the bolt is tightened evenly and prevent damage to the clutch. Tighten the bolt in a criss-cross pattern to ensure even distribution of torque.

It is important not to over-torque the bolt, as this can cause damage to the clutch or other components. On the other hand, under-torquing the bolt can cause the clutch to slip or wear out prematurely. Double check the torque measurement with the manufacturer’s specifications to ensure that the bolt is tightened to the correct measurement.

  • Step 1: Align and seat the clutch properly.
  • Step 2: Use a torque wrench and socket to tighten the bolt.
  • Step 3: Tighten the bolt in a criss-cross pattern to ensure even distribution of torque.
  • Step 4: Do not over-torque the bolt to prevent damage to the clutch.
  • Step 5: Double check the torque measurement with the manufacturer’s specifications.

By following these steps, you can ensure that the clutch bolt is torqued properly and the clutch is installed correctly. This will help prevent any potential damage or premature wear to the clutch or other components, and ensure smooth operation of your vehicle.

Expert Tips for Maintaining Your Ski Doo Clutch

Regular Inspection: It is essential to inspect your Ski Doo clutch regularly for any signs of wear and tear. Check the belt for any cracks, fraying or excessive wear, and replace it if necessary.

Proper Lubrication: Proper lubrication is critical to ensure that your Ski Doo clutch operates smoothly. Make sure to use the recommended lubricants, and avoid using too much grease, as it can cause clutch slippage.

Adjustment: Proper adjustment of the Ski Doo clutch is necessary to ensure optimal performance. Check the clutch’s alignment, the belt deflection, and the spring tension regularly, and make any necessary adjustments.

Storage: If you are storing your Ski Doo for an extended period, remove the drive belt and store it separately to prevent it from developing flat spots. Store the clutch in a dry place, away from direct sunlight, and avoid storing it on concrete, as it can absorb moisture.

Professional Maintenance: If you’re unsure about maintaining your Ski Doo clutch, it’s best to seek professional maintenance. A trained technician will inspect, clean, lubricate, and adjust your clutch to ensure optimal performance and extend its lifespan.

3 Tips for Proper Clutch Maintenance

Maintaining your Ski Doo clutch is essential for keeping your snowmobile running smoothly. Here are three tips to help you properly maintain your clutch and extend its lifespan:

Regularly clean and inspect the clutch: Dirt, dust, and debris can build up on the clutch, affecting its performance. Make sure to clean the clutch regularly and inspect it for any signs of wear or damage.

Use high-quality oil: Using high-quality oil is essential for keeping your clutch in good condition. Low-quality oil can cause slippage, overheating, and premature wear, so always choose a high-quality oil that is designed for your specific Ski Doo model.

Avoid aggressive riding: Riding your snowmobile aggressively can put unnecessary stress on the clutch, causing it to wear out more quickly. To extend the lifespan of your clutch, avoid aggressive riding and use your snowmobile in a responsible manner.

By following these simple tips, you can keep your Ski Doo clutch in good condition and ensure that your snowmobile runs smoothly for years to come. Remember to always consult your owner’s manual for specific maintenance instructions and to seek the help of a professional mechanic if you are unsure about any aspect of clutch maintenance.

Common Clutch Problems and Solutions

Slipping Clutch: This is one of the most common clutch problems that snowmobilers face. It occurs when the clutch is not gripping the belt firmly, causing the engine to rev up without the sled moving. The solution to this problem is to adjust the clutch properly, tighten the belt, or replace the worn-out clutch parts.

Clutch Drag: This is another common problem that can happen when the clutch is not disengaging fully. This can cause the sled to move even when the clutch is not engaged. To solve this problem, you can try lubricating the clutch parts, adjust the clutch properly, or replace the damaged or worn-out clutch parts.

Noisy Clutch: A clutch that makes a lot of noise is another common problem that snowmobilers face. This can be due to worn-out or damaged parts, misaligned clutch components, or lack of lubrication. The solution to this problem is to inspect the clutch parts, replace the damaged parts, realign the components, and lubricate the clutch properly.

When to Seek Professional Help for Your Clutch

Warning Lights: If the clutch warning light comes on, it’s a sign that something is wrong. You should immediately stop driving and take your Ski Doo to a professional mechanic.

Unusual Noises: Strange noises from your clutch may indicate that the components are worn out or damaged. If you hear any unusual sounds while driving, it’s best to get your clutch checked by a professional.

Difficulty Shifting Gears: If you’re having difficulty shifting gears, it may be due to a problem with your clutch. A professional can diagnose the issue and determine whether you need a repair or replacement.

If you notice any of the above signs, it’s important to seek professional help for your clutch. Trying to fix the problem on your own can cause more damage and result in costly repairs. A professional mechanic has the knowledge and experience to diagnose and repair your clutch correctly, ensuring your safety on the road.

Frequently Asked Questions

What tools are needed to disassemble a Ski Doo primary clutch?

Some of the tools you will need to disassemble a Ski Doo primary clutch include a clutch puller, a large wrench, a torque wrench, a vise, and a set of pliers.

What are the steps for removing the clutch from the engine?

To remove the clutch from the engine, you will need to loosen the clutch bolt, remove the clutch cover, insert the clutch puller, tighten the puller until the clutch pops off, and finally, remove the clutch and spacer from the engine.

How do you disassemble the clutch components?

To disassemble the clutch components, you will need to remove the bolt, washers, and clutch pieces from the spider. Then, you can remove the spider from the engine and take out the spring and slider shoes.

What is the purpose of cleaning the clutch housing?

Cleaning the clutch housing is important to ensure that the clutch operates smoothly and efficiently. Dirt and debris can cause the clutch to slip or fail, so it’s essential to clean the housing thoroughly before reassembling the clutch.

How do you properly torque the clutch bolt?

After cleaning the clutch components and reassembling them, you will need to torque the clutch bolt to the manufacturer’s specifications. This typically involves using a torque wrench to tighten the bolt to the recommended setting, which can vary depending on the model of Ski Doo.

When should you consider seeking professional help for your clutch?

If you are unsure about how to disassemble or reassemble your Ski Doo primary clutch, or if you encounter any issues during the process, it may be best to seek professional help. A trained technician can diagnose and repair any problems with your clutch to ensure that it operates safely and efficiently.

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