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I just went through this on an '01 1000 that had never been removed. Tried most of the tricks mentioned above with success and have two thoughts:
If you don't want to use a torch, use a small 1100watt fan heater, turn it on facing down on top of the primary and wait an hour or so. It will heat the aluminum up slowly and avoid any potential damage from overheating witha torch. The steel crank won't heat up at all so the aluminum will expand and help free itself. As said before, pump grease in, grease the threads on the puller good, a few layers of teflon tape and get a good cheater bar. It will sound and feel like you broke something when it gives. Smile, you won.
And don't be fooled by the "cheaper" clutch pullers out there. I twisted one of the cheaper ones up, so save yourself some time (and $$) and make sure its high grade metal. good luck,
oZ
If you don't want to use a torch, use a small 1100watt fan heater, turn it on facing down on top of the primary and wait an hour or so. It will heat the aluminum up slowly and avoid any potential damage from overheating witha torch. The steel crank won't heat up at all so the aluminum will expand and help free itself. As said before, pump grease in, grease the threads on the puller good, a few layers of teflon tape and get a good cheater bar. It will sound and feel like you broke something when it gives. Smile, you won.
And don't be fooled by the "cheaper" clutch pullers out there. I twisted one of the cheaper ones up, so save yourself some time (and $$) and make sure its high grade metal. good luck,
oZ