Drive clutch removal

[Supersport6]

Hi all. I need to remove the drive clutch from my 97 gas cart. What thread does the puller have. I can't see paying $40 for a bolt that I can make. Also will the clutch come off with the engine in place? It looks very close to the frame. Thx, Rod.

[Heliarc]

If you've only got an inch or so of clearance between the frame and the clutch I would say that your engine must be at least loosened enough to jack the side up for the clutch to clear. My problem is that I'm not familiar with the later model carts like yours. On mine I can unbolt two engine mounts and jack the engine up enough for the clutch to slide off of the crank when it comes loose. Also on mine I used a 3/4" grade 8 fine thread bolt and a piece of mild steel round stock so I wouldn't mar the end of the crankshaft when pulling. I'm not sure of the dimensions for yours but if you did get the entire engine out you'd be able to run it down to a hardware store and try a few bolts. Barring that, $40 isn't much compared to what you've spent merely purchasing the cart and what you'll spend on it in the future. Anyhow, assume that the 3/4" fine thread bolt is not going to work for your clutch until you prove otherwise. Another thing if you don't want to remove the engine. Put the cart on your truck or trailer and run the entire thing to the hardware store. If you've got a gearhead in there he might be able to get you the proper round stock you need as well.

You'll also need a manner of keeping the clutch from spinning as you run the puller in. This could be a strap wrench around the clutch, or what I did was to use a large pipe wrench on the inside shaft of the clutch. The belt pretty much never rides there so a few tooth marks aren't going to hurt it. You could file them down afterwards if it really bothered you as well.Another method I've heard of and makes sense to me is an air impact wrench which would shock the taper lock while it's turning the puller. If your engine is out and you have access to one, this might be the way to go.