How do I remove clutch on ZR 120?

[ProBell]

Any one know how to remove the front clutch on a ZR 120? It is a aftermarket clutch. What is the best way to stop the motor from turning wile trying to loosen the retaining bolt?

[justasquid]

I've never worked on a 120, but on other snowmobiles I've owned, I would use a piece of nylon rope down the sparkplug hole into the cylinder. This will stop the piston from being able to come up any higher, which in turn prevents the crank from spinning. Although, I've never done this on a 4 stroke, and I don't know how it would all play out with the valves in the way.

If it was me, I would probably just use an impact and hold onto the clutch. The bolt shouldn't be torqued that much since the bolt isnt really holding the clutch on, the taper is. The bolt is only used to press the clutch into place, then there to prevent the clutch from coming off. Its not holding much load on its own. At least on larger snowmobiles its not.

I did do a quick google search and turned up that people wedge wooden handles or screwdrivers between the clutch slots. That seems a bit of a risk, but it probably does work. You could also probably use some sort of a belt, wrap it aroud the outside of the clutch, then tie off the other end to a part of the chassis. That should give enough stoping force to get the bolt off an retightened.

Also, once that part is done, you will need a clutch puller to get the clutch off of the crankshafts taper.