cannot remove doodlebug clutch

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MtnXfreeride

New Member
#1
#1
I am trying to install the jackshift kit. I did get the bolt off in this is a newer style Doodlebug. I also took the snap ring of the clutch and remove the cover. Is there anything else that could be holding this clutch on? I don't see anything else no bulbs are hidden nuts or screws. I blasted it with penetrating oil, I tried gently pulling, I tried wrapping a small crowbar with a rag and I have also tried tapping it with a rubber hammer. Oh and I tried warming it with a heat gun. Now that I'm looking into it on the foum, I keep seeing people who have ruined their clutch so now I'm worried I will break something. Are there any other techniques, or hidden attachment on this clutch for the newer Doodlebug that I should know about?



Im kinda mad there was no heads up of issues like this with the jackshift kit.. I just needed a new chain which was my reason for upgrading to this kit in the process. Had I known clutch damage was a high possibility I would have just stuck with a chain.
 
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ludicrous speed

ludicrous speed

New Member
#2
#2
those shoes r spring loaded take em off and put the bolt back in a couple of good threads maybe more,No washer/bolt only and use a 2 jaw puller or a 3 jaw puller on it.
at least you can grab those edges back there with the puller jaws.
work it Slow and stop and reset if it tries to go offside/the puller<
we had this happen awhile back.
 
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Camjamsdad

Active Member
#4
#4
You are the minority. Somebody probably boogered up the shaft before you. Somebody posted up pix of their home made tool to remove stuck clutches. It was a piece of rectangle tube with a slot cut in to slide around the engine shaft then he welded a nut inside. Not easy to visualize but a simple tool when you can picture it
 
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chazdaddy

New Member
#5
#5
I use a long screwdriver placed between the crankcase and clutch to apply outward pressure. Then I screw in the retaining bolt with the washer almost all the way. The washer is to keep the clutch from flying off when it comes loose. Then I lightly tap the head of the retaining bolt with a hammer while pulling on the screwdriver. Take it slow and easy, so you don't break/ bend something. It should pop right off.

After you get it off, file any burrs on the crankshaft and clutch bore so the clutch slides on/ off easy. I usually apply a little grease on the crankshaft before I slide on the clutch for anti-seize.

Jackshaft didn't cause you problem IMO. Good luck getting it off.

I think you have old style DB30. :shrug:
 
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chazdaddy

New Member
#8
#8
If that's an OEM 97cc clutch, there is no set screw. If it's an after market clutch for 5/8" crank, I see your problem. If so, someone crammed a 5/8" ID clutch onto a 16mm OD crank. The difference is approx .005", it will be very hard to get off, may take a grinder. :shrug:
 
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MtnXfreeride

New Member
#10
#10
chazdaddy said:
I use a long screwdriver placed between the crankcase and clutch to apply outward pressure. Then I screw in the retaining bolt with the washer almost all the way. The washer is to keep the clutch from flying off when it comes loose. Then I lightly tap the head of the retaining bolt with a hammer while pulling on the screwdriver. Take it slow and easy, so you don't break/ bend something. It should pop right off.

After you get it off, file any burrs on the crankshaft and clutch bore so the clutch slides on/ off easy. I usually apply a little grease on the crankshaft before I slide on the clutch for anti-seize.

Jackshaft didn't cause you problem IMO. Good luck getting it off.

I think you have old style DB30. :shrug:
Click to expand...
I realize jackshift didnt cause the problem... I havent installed it yet. I wish they were more open about tools needed, risks involved, and posted instructions openly so I could have had it ready to throw on before ordering.
Im stuck on step 2! Also 100% sure its an older doodlebug... I said wrong above and it wont let me edit it.
 
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chazdaddy

New Member
#12
#12
If you have to grind it off, might help to remove the shoes 1st. There is a retaining ring that holds the shoe retainer plate onto the hub. Remove the retaining ring and the shoes/ spring will come off.

Problem is, if you don't already have a good set of retaining ring pliers they are fairly expensive. Then after the clutch comes off damaged or OK, you will need a real DB30 clutch, more $'s.

I haven't had this issue with 97cc, but with Briggs flatheads I have removed several rusted on pulleys that took a lot of effort/ time to get off. I feel your pain.
 
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MtnXfreeride

New Member
#13
#13
Went to harbor freight after work to get a gear puller $16. It took an amazing amount of force before it left go and came off. The clutch looks pretty bent, Im assuming it is broken. I ordered another one.. more $$$ :(

No rust there, just really stuck on. It would have been impossible by hand to pull that off. Hopefully this is the last part Ill be needing for a while, and I really hope I didn't damage the engine at all with all my yanking.

I do have decent snap ring pliers to the person above.. they were probably $25 - but the tip snapped on the second ring of that clutch... Im just going to call this the devil clutch.
 
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iStone

New Member
#16
#16
I'm having the same issue with my flywheel on my Predator. I think I'll go pick up one of those pullers from HF tonight after work. Damn thing feels like it's welded on!
 
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Camjamsdad

Active Member
#17
#17
iStone said:
I'm having the same issue with my flywheel on my Predator. I think I'll go pick up one of those pullers from HF tonight after work. Damn thing feels like it's welded on!
Click to expand...
Those predator flywheel can suck bad. I broke one of the h bar bearing separator tools from harbor freight. One arm snapped off. What's funny is i've pulled 2 97cc wheels just by unbolting it and giving it a couple taps with a small dead blow hammer
 
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