Clutch puller broke/mushroomed

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Nielv

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2004 RX1
dealer says I'm in trouble. Apparently I bought a cheap clutch puller and it broke inside primary and mushroomed so I couldn't remove it. Dealer is not sure what to do and said they would call Yamaha Monday. My buddy said we might have to cut back half of primary to get off shaft. Any advice would be appreciated. Thank you!
 
If it still has threads you should be able to back it out with a square easy-out or reverse drill. If it broke beyond the threads you can still get your primary off using a hollow bolt with smaller bolt threaded into it. Using grease provides a hydraulic action to pop the clutch off. The biggest issue is to not damage the engine or bearings. Remember that the clutch puller presses against the end of the crank to pop the clutch off. The hollow bolt works well if the broken piece is not into the threads. Post up a close-up pic if you can.

Where are you located?
 
Thanks Ding! I am located in Mokena, IL. Dealer is calling Yamaha Monday. I will call in afternoon and see what they say and give them your advice. Thanks again.
 
I will post a pic if dealer can't fix. Thank you again for input.
 
What snowmobile are we talking about? You are in the Nytro MTN forum but list an RX1 as your ride? In any case, both sleds use output shafts that are not part of the crankshaft.
 
I have both but this issue is on 2009 Nytro MTX.
Thank you
 
Yes, MountainTech is right - the output shaft is separate from the crank. For some reason I was thinking 2 stroke, sorry. That is what I get for reading both sites at the same time.

In any case you should be able to get it off. Post up a well-lit closeup of the clutch bolt hole.
 
OK. I have the sled back and am trying to attach a picture I took with snake camera showing the inside of primary and broken puller. Any suggestions on how to get primary off?
 

Attachments

  • Nytro Primary.jpg
    Nytro Primary.jpg
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If you can thread something into that hole you could try putting the sled on it's side and filling the clutch up with oil and then screwing a bolt or the threaded end of the clutch puller in there. In the hope that hydraulic pressure might pop off the clutch.
 
sxr70001 said:
If you can thread something into that hole you could try putting the sled on it's side and filling the clutch up with oil and then screwing a bolt or the threaded end of the clutch puller in there. In the hope that hydraulic pressure might pop off the clutch.
Click to expand...
Thank you. I will try
 
Yes, it looks like you have room to use hydraulic pressure to pop the clutch off as mentioned above.
 
I've seen a video that said to use hot water. Maybe hot oil would work too. If getting to the desperate stage, I would use cold gear oil and heat the sheave hub with a torch to expand the metal. If it's that tight to break the puller, it might take take to get it off.
 
Heating it is ok in moderation, just be careful with it. Use teflon tape on the bolt and tighten and let sit, then repeat. I have seen where it took a day or so to finally pop loose. The bolt uses the clutch puller threads in the clutch of course, not the shaft threads. Use a good bolt - I prefer grade 10.9 bolts for this.
 
If you unbolt the reduction and remove whole assembly from engine you could likely use a press to drive the reduction shaft out of the clutch.
 
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