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Disassembly Removal and Installation
The first thing you need to do is get your floor board off your bike. once the floor board is off you will be looking at the clutch housing. some bikes have an all aluminum clutch housing, some bikes have an all black powdercoated aluminum housing and some bikes have a black plastic housing. regardless of which bike you have the disassembly and removal of the primary and secondary clutches are basically the same. here is your clutch housing, you need to remove all the housing bolts from around the housing and BE SURE to note that there are 2 long bolts towards the rear of the housing. be sure you note which holes the longer bolts come from because they will need to go back in the same location.
After you get the housing off you will be looking at your primary and secondary clutch. the primary clutch is the smaller clutch towards the front of the bike. the secondary is the larger clutch towards the rear of the bike.
The FIRST thing you will need to do is take one of the long case bolts, or a 6mm bolt and thread it into the threaded hole in the secondry towards the center of the pulley. run it down untill it stops. doing this releases the belt tension and allows disassembly and reassembly to be alot easier
The next thing you need to do is take the primary nut off. some bikes have a different sized nut, this particular H1 bike has a 32mm nut holding the primary on.
Pull the entire outter half of the primary clutch outwards towards you. it is an aluminum sheave, with a fixed plate (yellowish metal plate) and it also has rollers inside. be sure to put both hands on the outter half of the primary and pull outwards sliding the outter half off the shaft. there is a black metal sleeve that the outter sheave slides back and forth on. if the sleeve does not come out on its own with the outter half of the primary, just slide it off after the outter sheave comes off.
Next pull your belt over the shaft and off the bike
Then pull the inner half off
For stage 1 - i only need the inner and outter half of the primary clutch, JUST the aluminum sheaves
For stage 2 - i also need the yellowish fixed plate and the rollers
For stage 3 - i also need the black sleeve
Your entire primary should look like this when completely taken off the bike and laid out.
to pull the secondary off you need to first back the case bolt or 6mm bolt out of the threaded portion of the secondary, and use a 36mm socket to remove the secondary nut. then the secondary pulls straight outwards and slides off its shaft
This is the entire clutch setup out of an arctic cat. i need everything in this picture for my stage 5 clutching. the entire primary assembly, and the secondary.
Reassembly is just the opposite of disassembly. and remember ALWAYS USE RED LOCTITE on the primary AND secondary nut on reassembly
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Airdam Special
