Ski-Doo recommends cleaning the clutch on your snow sled every year or every 2,000 miles. The clutch on a Ski-Doo is actually a two-part, sliding pulley. It's accessed from the left side of the vehicle, under the left-hand side panel along with the tool box and the air-intake silencer. Before you begin to disassemble and clean the clutch, though, you need to make sure the Ski-Doo is on level ground.
Apply the Ski-Doo's parking brake and ensure its shifter is in neutral. Start the engine. Release the parking break and make sure it doesn’t creep forward. Check the idle speed to verify that it is correct. Shut the engine down. Remove the drive belt guard and the drive belt from the engine.
Insert the pin on the drive pulley holder, part No. 529-027-600, into the hole on the drive pulley, to prevent the pulley’s movement. Slide the drive pulley puller, part No. 529-022-400, through the pulley, hold the pulley with the pulley holder and screw the pulley puller into the pulley. Back the puller out, bringing the pulley with it, using an adjustable wrench. Remove the drive pulley.
Move to the other end of the pulley and unscrew the nut on the pulley shaft. Remove the nut and washer from the pulley shaft and remove the drive puller cap. Take note of the alignment marks on the cap and on the side of the sliding half of the assembly. Doing this will allow you to index the screws properly when you’re reassembling the clutch.
Mark the blocks and calibration weights on the sliding half with a pencil mark, so you can return them to the correct location during reassembly. Remove the blocks and calibration weights from the sliding half and install the spring cover tool, part No. 529-027-300, and the drive pulley puller onto the spring cover. Tighten the pulley puller until hand tight, remove the two screws holding the spring cover in place and set the assembly aside.
Unscrew the pulley puller slowly, to release the tension on the spring. Set it aside and remove the spring cover, the spring and the spring seat. Clean the pulley faces and the pulley shaft using fine steel wool. Wipe dry with a clean, dry cloth. Clean the sliding half bushing with a clean, dry cloth. Inspect the pulley surfaces for excessive scratches and wiggle the sliding half, to check for excessive play.
Reinstall the spring seat, then replace the spring and spring cover. Reinstall the blocks and their weights with the curved end facing inward toward the governor cup. Replace the washer and nut on the pulley shaft and tighten the nut to 95 foot-pounds. Apply thread locker to the screws and torque the screws to 19 foot-pounds.
Wipe the inner pulley taper and the driveshaft taper with Ski-Doo’s proprietary pulley flange cleaner. Thread the drive clutch bolt through its lock washer. Reinstall it into the drive pulley and tighten the bolt to 66 foot-pounds.
- The drive pulley spring is compressed and held in place by a nut and a lock washer that's tightened to 95 foot-pounds. That represents a tremendous amount of force that can cause significant bodily damage.
- After you complete the re-installation, start your Ski-Doo in neutral and watch it to see if it creeps forward. If it does, that indicates your drive belt needs adjustment.
- Bombardier Recreational Products: 2013 Ski-Doo REV XS XM 600 HO / 800R E-Tec Snowmobile Series Repair and Maintenance Manual
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