Today I worked on my 81 Trailfire 440 in preparation of installing my rebuilt engine. I drained all the fuel out of the tank. Installed a new Mikuni Fuel Pump and removed the secondary clutch! I needed to remove the clutch so that I could use the clutch alignment tool when I drop the engine in to line the clutches up properly. The problem was that the secondary Clutch was STUCK on the shaft! I removed the bolt and washer per the manual and it wouldn't budge. Then I tried spraying PB Blaster on it and letting it soak. While it was soaking, I held the brake and grabbed the clutch and jerked it back and forth as hard as I could. Still wouldn't budge. I even tried lightly tapping the clutch with a brass hammer and it still didn't budge. So then I came up with an idea to get it off and it came off really easy!
Tools used
1. Heavy duty flywheel puller that I purchased from New Breed Snowmobile Parts to get my flywheel off.
2. A 3/8" Craftsman short extension with a 1/2" socket on it.
3. Twelve 1/4" washers.
4. Three 5/16"-18 bolts 2" long.
5. One 5/16"-18 bolt 3/4" long.
6. One long 1/4" Drive extension with a 1/2" socket
7. A 1-1/8" wrench or socket with a breaker bar will work too.
Step 1 - Remove bolt and washer per the manual and set aside.
Step 2 - Install the 5/16"-18 bolt that's 3/4" long down inside the shaft. Use a 1/4" drive long extension with a 1/2" socket to install the bolt. The 1/4" drive sockets are thinner and slide past the key.
Step 3 - Remove the three 5/16"-18 bolts one at a time and replace them with 5/16"-18 bolts 2" long bolts with three 1/4" washers installed through the flywheel puller. This keeps the clutch from coming apart due to the spring pressure.
Step 4 - insert the 3/8" Craftsman short extension, with a 1/2" socket on it, inside the shaft and make sure the socket engages bolt squarely.
Step 5 - Make sure the pointed tip of the flywheel puller's center bolt fits on the female square hole of the extension.
Step 6 - Start cranking on the center bolt on the fly wheel puller with the 1-1/8" wrench. My clutch began to easily slide off, the shaft as I was turning the center bolt on the flywheel puller.
Step 7 - Spread the two sheaves as far apart as possible and stick something between them to hold them apart. This makes the clutch narrower and able to slide off the end of the shaft.
That's it! I hope this helps someone else in the future if they run across a stubborn Secondary Clutch. Sometimes you just have to get creative with tools you have!
Sorry no picture of it off! Trust me its off!
Hec