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Clutch puller tool

This is a discussion on Clutch puller tool within the Full Size Ranger Discussion forums, part of the Polaris Ranger Forum category; Well...my starter went out on my 2005 Polaris Ranger 500 4x4. After I find the engineer who designed the thing so that I have to ...

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Old 08-16-2012, 10:52 AM   #1
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Clutch puller tool

Well...my starter went out on my 2005 Polaris Ranger 500 4x4. After I find the engineer who designed the thing so that I have to pull the clutch and backing plate and resist the temptation to stomp the tar out of him, can somebody tell me what size clutch puller I need, and can I find it locally at possibly an auto parts store? Or is this one of those things that can only be found online (I'm guessing a dealership won't have it because they want to do the work for you)? Again, it's a 2005 plain Polaris 500. Any help would be appreciated.
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Old 08-18-2012, 08:40 PM   #2
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I was just talking with my buddy yesterday - he had to replace the brushes on his Ranger's starter, and had to pull the starter to do so. He told me how bad it was getting it off, but in his case he pried and muscled the clutch cover until he was able to force the starter out of there.

When he put it back together, he cut about 1/4" off one of the bolts (I think he said the bottom one) so he could get it back in without having to pull the clutch off.

So maybe you can try doing it without removing the clutch?

Hope this helps.
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Old 08-19-2012, 08:29 AM   #3
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Originally Posted by Russ Chastain View Post
I was just talking with my buddy yesterday - he had to replace the brushes on his Ranger's starter, and had to pull the starter to do so. He told me how bad it was getting it off, but in his case he pried and muscled the clutch cover until he was able to force the starter out of there.

When he put it back together, he cut about 1/4" off one of the bolts (I think he said the bottom one) so he could get it back in without having to pull the clutch off.

So maybe you can try doing it without removing the clutch?

Hope this helps.
Thanks. I was given the same advice and tried very hard to do the same thing. I even used a big slate bar to pry that cover back. But I still couldn't get the clearance to get it out. I have the clutch puller tool coming to me tomorrow. It's just a terrible design for a routine "wear and tear" part.
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Old 08-19-2012, 08:35 AM   #4
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I hear that.

My friend started to pull the clutch but said he didn't like the way his puller was acting - didn't think it would do the job properly without messing something up. So he was able to muscle through. But they may have changed the clutch covers between his model (2002) and yours. I hope mine (2006) lasts forever!
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Old 08-19-2012, 04:36 PM   #5
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The engineer that designed that actually came home one day and found his wife , ummm, being entertained, by a mechanic. I guess he figured he could make that mechanics life hell for a lot longer
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Old 08-21-2012, 09:29 PM   #6
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Success! Got the puller today and got the primary off. Unbolted the secondary and the backing plate. Replaced the starter and I'm back on the road. For those of you that want to know, it takes a "PCP-1" primary clutch puller.
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Old 08-22-2012, 09:52 AM   #7
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Originally Posted by Hillbilly View Post
Success! Got the puller today and got the primary off. Unbolted the secondary and the backing plate. Replaced the starter and I'm back on the road. For those of you that want to know, it takes a "PCP-1" primary clutch puller.
Congrats!
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