I have exhausted all possibilities of intact removal. A correct removal tool likely would have changed this outcome. As for how much wear this Pilot has, It has a lot of hours on it but I took good care of it. It could use a fresh top end but I need to deal with things one at a time. Right now the clutch is the biggest problem.

I used an impactor to tighten the bolt until it stopped turning then wedged 2 crowbar on the Engine side. I used successfully larger hammers unil I became concerned with possibly damaging the Engine. It's not coming off and it's too late for the correct removal tool. If all I need is a new clutch I'm okay with that if it gets the machine running.

There's only so much time to ride left in California anyways. OHV's have to be electric by 2035 and no exceptions for old equipment. Knowing how this state is managed it wouldn't surprise me if they did it sooner. We're losing Oceano Dunes (AKA Pismo) end of this year already.

Photo

The pry bar thing is a bad idea because you can fracture the aluminum side cover.
Just to verify --- you hit the head of the pusher bolt with the hammer right ?
CO

EDIT: At worst you can unbolt this clutch and take it apart piece by piece and then when you are down to the inside shiv on the crank you can make a custom puller.
You could also take it apart piece by piece to get your pusher out and then bolt it all back together and try again with a correct clutch removal tool.
DON'T HACK IT APART !
CO

Yes, I was using the hammer on the removal bolt. I also sprayed PB Blaster lube inside the hole..
I will try to disassemble the clutch. I already removed the large bolt. I'll have to read the manual on how to get the inner workings out. I don't want to cut the clutch apart but I might not have a choice. It's a tough lesson to learn removing the clutch but sometimes that's the way it is. I've done lots of servicing on this machine including working on the rear axles which are notorious for being hard to remove and I was able to get it done. I've met my match with this clutch.

Taking the clutch apart will not help. You can remove the outer cover as seen in my pics in the link, going by memory its only 3 bolts and has a O-Ring seal.

Keep the Engine vertical, remove the puller bolt, using the PB Blaster with the straw stick it straight down into the hole spray bout 4 table spoons of PB in it, you have to over fill the threaded hole once over filled it will seep in the area where the clutch taper is. Allow it to soak 24 hrs in the vertical position.

While your waiting search the site for Pilot clutches and crankshafts look them over close so you get a good understanding whats inside and your working on.

Just to be clear you want the push pin to bottom out in the hole that the bolt that holds the clutch on threads into )hole in the end of the crank) then your puller threaded bolt end will push against the pin pushing on the bottom of the hole, if you have a one piece puller (actually a pusher lol) it will work the same.

Tighten the bolt as tight as you can tap with the hammer, tighten again, hit it with the hammer again, repeat a few times it should pop off..

Thing I HATE about the one piece pullers is I have seen the un-threaded part of the puller bend inside the hole and get stuck, that is why I build my own two piece puller out of a punch, the punch will not bend. http://pilotodyssey.com/PO/viewtopic.php?t=3324