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1999 Kawasaki Mule 2500 Primary Clutch Dissassembly

Mikey

By Mikey
in Kawasaki UTV SxS Forum

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Mikey Contributor

Mikey

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I am trying to dissassemble my  primarty clutch. I removed the obvious bolts and separated the main mechanisim cover from the body of the clutch but I cannot see how to separate the thin sheave from the body of the clutch. I am guessing it is threaded to the splined shaft. Not sure if it is a right hand or a left hand thread.  Anybody have a source for dissassembly instructions?   I already tried Youtube with no results.

Many thanks, Mike

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Mikey Contributor

Mikey

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@Travis Many thanks for the quick reply.  I am dissassembling a used and "supposedly" good clutch. Mine looks exactly like the exploded view you sent. I did check my manual as you suggested and I don't see the 2 pieces of 92022 split ring in my clutch making me think that maybe they are missing. However my spider (49050) seems frozen to the thin sheave shaft (59302).  I sprayed the spline well with penetrating oil and hit it pretty hard with a hammer but the splined shaft will not budge from the spider.  I hate to ruin the clutch as they are quite expensive and I was happy to get this "working" clutch on a bad engine I bought last week to rebuild just to have a spare for my mule.  Any other ideas?   Do you recall removing you split ring and have any advice there. I wonder if the split ring could be jammed inside the spline? Here is a close up pic of the position between my spider and the splined shaft of the thin sheave. They are locked fast together and I see no evidence of a split ring????? 

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Mikey Contributor

Mikey

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@Travis Hi Travis,  Many thanks but I put it in a big press and finally got it to come apart. The spline connection was  really corroded from sitting I think outside in the rain. The split ring is there but on the other side of the spider. i have a lot of cleaning to do but I think it will be a good clutch when I am done.  Many thanks for the help once again!

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