[huntindog]

I have a 2004 650 V2. The primary clutch has never been off, and it's stuck on the crank tight.
The threaded hole for the removal tool has already given up it's threads.
So I started disassembling the clutch to see what my options are.

The shaft has holes drilled thru it on the end....I am considering putting a bolt thru these holes, with a chain hooked to it and winching on it with my Chevys warn winch.
Might have to tie the quad off somehow to get enough pull on it.

Probably heat it up with a torch as well while it's under tension.

Option two is to finish taking apart the clutch and carefully cutting
the inner sheave
off with a grinder. Not thrilled about this option as at a minimum I'll need a new inner sheave.

Ideas?

 

[spooln30]

Wow, I've never heard of this. I wouldn't attempt the winching idea, you'll probably break the clutch it's aluminum. Spray it up with a lot of PB Blaster then after 30 mins spray it again. Should help get it off. After the Blaster just try tapping it off with a dead blow hammer and some heat but not a lot. There's seals inside the clutch where the spacer rides inside the plates. Btw you probably did but did you remove the nut? Just checking. Where do you think it's seized? On the splines or the drive face spacer?

 

[doorfx]

It's a v2 clutch not like a cat clutch. It's a kawi motor

 

[huntindog]

Update. I tapped the hole for a 5/8 coarse thread bolt. Cut a 3/8 metal rod to the right size and put it in the hole, followed by the 5/8 bolt. meanwhile it has been soaking in WD 40 blue torch.

Heated it up and gave it a go.

Still won't come off. That was yesterday. Overnight I tipped up the right side and supported it with a jackstand so I could fill the hole
with blue torch. gonna give it another go today.

The winch idea has been put on hold for now. That will be a desperation move. At this point In just need to get it off without damaging the crank.