Apr 22, 2009. (part 1) Remove shifter, free up top of trans. Will not work on clutch baskets with reversed inner clutch hubs where the integrated clutch faceplate is facing outward. Mark it and put it back in the same holes it came out of. Repeat Steps 8, 9 and 10 to achieve .001-.010" clearance with . After pulling that clutch assembly off, simply give it as is to someone you dont like. Prevents clutch damage. To my pleasant surprise, this technique works GREAT!!!! Remove the clutch actuator rod from the primary cover. 4.8 out of 5 stars 11. 7 Those dark grey indents are where the friction plates' location lugs whack into the clutch basket. Remove clutch lever from bracket and pull anchor pin from cable. Done. S. Yesland 2 Pack Spanner Wrench, Adjustable Wrench Holder, Clutch Hub Rotor Sprocket Spanner Wrench Set & Fan Clutch Removal Tool Accessories for Scooter, Motorcycle. First i tried by putting the bike in 1st gear and apllying the rear brake, no succes. Newer models (2013-present) do not use a snap ring. Remove the lockplate from the rear of the basket, then take the clutch to the press and separate the hub and the basket. - Shifter Fork Alignment. The penny is soft enough that it will bend before any possible damage could be done to other parts. Recommended for square tooth style clutch hubs. Join the discussion. Unscrew the spanner clutch drum . Reinstall your pushrod, retainer marked "OUT' on the side that faces out and your adjustment screw and nut. Made in the U.K.by EBC Brakes, these laser-cut clutch tools make clutch removal, loosening of the drive shaft bolts and re-tightening a breeze, without any fear of damage to your expensive clutch basket. Continue with Google. EBC - CT003 - Clutch Removal Tool Suzuki RM 125. . Next with chisel and hammer, make a detent on the clutch hub nut. Made in the UK by EBC Brakes, these laser cut clutch tools make clutch removal, loosening of the drive shaft bolts and re-tightening a breeze, without any fear of damage to your expensive clutch basket. Speeds clutch removal. It's two "big freaking nuts", one of which is reverse threaded, but not a big deal. Step 5. Figure 4. (Figure 14) Remove two T-27 Torx screws with washers from clutch bracket. 99. . A lot of it stayed stuck pretty hard on the . If the engine is in the tractor with the PTO disengaged you should be able to turn the PTO body separate from the star disc to align it with the holes. $26.99 $ 26. Expertly crafted from the highest grade . Learn helpful tips in this video. Step 4 - Remove the starter "nose". May 20, 2012. you have to have the cluthes in to bind the clutches to hub, the main will spin if it is in gear., but that wont help you, you need to hold the hub in place on the main, so like I said, if you use an impact, thats good. Examine the shift ratchet, primary drive gears, and everything else you can see with the cover off. Good video. You will need a jam nut tool, and a spider holder AFAIK (as far as i know). 4.3 out of 5 stars 246. Features 8mm spanner pins. but i like to use the clutch plate with a handle to torque it correctly. 6 Pull the old plates out in one go. Transmission cover before removal. 1 - 4 of 4 Posts. When the clutch on my stock 850 Commando began to slip at high r.p.m. All you need is your Bad Boy Serial Number to find all of the diagrams for your unit. Remove the starter to get the hook around the ring gear on the top and don't overdo it. What tools do I need to remove the clutch basket? Re: Clutch tool. c o m c o p y r i g h t 2 0 1 5 This section shows how to remove the Clutch Basket. Use a flat head screwdriver to slide any remaining disks out of the basket. CT Series Clutch Removal Tool by EBC. I have to honestly say that I had my doubts about this procedure, but after unsuccessful trying to remove clutch with a make-shift puller and a slide hammer with heat applied, I resorted to the "grease gun" technique. Step 4: Once removed, carefully disconnect wires from the old clutch pulley using a wire connector. (it has the bronze metal plates) and no amount of adjustment seemed to cure the problem, I assumed a new clutch was in order. ! There are two long screws on one side, and two short ones near the output shafts (red arrows in Figure 4, plus two on the opposite side). Hey guys can anyone tell me a trick for removing the clutch hub nut. You will find a screw and locknut. If your replacing gears, which more than likely you will have to, since a shift fork replacement alone, rarely cures the jumping out of gear problem, you will need to remove the clutch basket and clutch hub off the transmission input shaft, to dissasemble the shaft. 8mm spanner pins on the back can also be used to hold flywheels, sprockets, gears, etc. Pity that he didn't tighten up opposite bolts when doing up the clutch pack bolts. You will probably need an impact wrench to do . Standard sockets & ratchets (American & Metric) Pliers (standard & needle nose) Allen/Hex head wrenches (American) Snap ring pliers Red & blue thread lock Torque Wrench Oil for primary (30-40 oz) (replacement after removing the primary) Appropriate gaskets & seals will come in the Harley forward control kit. Slacken the locknut, turn the screw in until it just bottoms out, then back it off about 2/3 turn. The other tool which might work is a . If . Frank also shows the proper method to reinstall the transmission into the frame with proper shimming and alignment. Step 1: Cut The Angle Iron At 1/3 Length. (Figure 15) Pull the clutch cable through the inner fairing to the front, just enough so it clears the fairing. I've reused the aluminium clutch cover bolts a couple of times and not . Yeah, you don't need to remove the pan. We carry only the finest quality specialty tools from top manufacturers like BikeMaster, Pit Posse Motorsports, Motion Pro, JIMS, and more. Step 1 - Drain your primary. Hello, you may be able to sneak it out without removing the clutch basket. At the advice of a local Norton shop, I did the following to the bike which quickly (and cheaply) remedied the trouble: . Secures clutch basket in order to remove clutch retaining bolt. Cost for the new bolts (grade 8 ) plus a total of 10 washers $4.30 (threw the stock bolts and washers away) In the few instances that I already had the engine out of the frame with the top end off (can't use the rope trick or put in gear with rear brake held), I put a penny between the primary gears to "jam" them while I broke the nut loose with a breaker bar/socket. We have the best prices on Bad Boy Parts Online! Reply #5 on: September 19, 2015, 11:21:30 pm . . I usually put it in the highest gear and wedge the tire someway. Re-install the shift shaft in its hole in the crankcase aligning the dogs on the star. First fit the damper spring SEAT - This is the slightly thicker of the . Adjustable jaws open up to 5 inches wide and are recommended for square tooth style clutch hubs. Strong zinc-plated carbon steel. Use the old plate stack as a reference for the new plates. - If you're replacing the outer basket, you should also be replacing the springs and plates. With the starter now out and on your bench, remove the front cover on the left end of the starter (as mounted). $8.27 $ 8. Any idea how it broke? Next I removed the clutch cable and foot shift lever, and loosened the bolts on the cover. Continue with Facebook. Aids in unlocking clutch retainer bolts. After you get the cover off, you'll be able to see the basket/plates. EBC CT003 Clutch Removal Tool. The bolt holes in the clutch are the same threads as the clutch cover. Here's a clear view of the Clutch Hub without the basket or any Clutch plates in the way. Turboprop said: If you are simply removing the '93 clutch basket to replace it with the '98 and basket, there is no need to compress the spring, buy any correct tools, etc. The keyway does not hold the clutch on, the taper does, it produces an interference press fit, and the bond is easily broken. My clutch was slipping for the past year and a half (in 5th and lately in 4th when hard on the gas). Flywheel Pulley Holder 330mm/13in Motorcycle ATV Clutch Flywheel Holding Tool Clutch Hub Basket Gear Holder Tool. Do not attempt to install the S&S clutch without . Bad Boy Mowers are what we do here at BadBoyMowerParts.com and we make sure that our customers get the correct parts the first time with out custom Bad Boy Mower Parts lookup system. If you have to remove the basket just be careful how you wedge it to get the nut off. And yes, you do need to remove the snap rings. If your just replacing shift forks the clutch assembly can stay on the transmission shaft. Step 2: Align The End Of The Angle Iron Pieces. Clutch cable and shift lever removed, transmission cover removed. marp68 Do not attempt to break this nut loose with a breaker bar, you will likely damage the clutch basket with the basket tool. Step 2: Now remove all of the screws from both sides of your compressor case cover and then gently lift upon it. the center clutch seems to be aluminum so those studs just don't seem to be strong enough to torgue that nut to 80 ft lbs. Be sure to arrange the new, oil soaked plates in the same order as the old ones and then slip the new plates into the basket. Make sure the retaining clip is completely seated in the slots in the little fingers. It also works when the clutch "grabs" when you are sitting with the clutch pulled in. Jaws open up to 5 inches wide. Replace your clutch plates in order. The primary locking tool is used to keep the basket from rotating and therefore the nut can be removed from the hub while the clutch plates prevent the hub . Jun 2, 2003. Use a Torx driver and bit to remove the four Torx bolts on the derby cover. Only use a heavy duty impact gun. Removing the Clutch Basket Norton 961 1 | P a g e r i c h a r d @ c o o t e 1 . - Once you have the plates out, you'll have to remove the large nut holding the baskets in place. The first place to do the adjustment is inside the black cover at the back of the engine. Aids in unlocking clutch retainer bolts. Ive tried like crazy to get this thing off but im afraid of rounding out the nut I ahve on order the clutch hub pliers to hold the hub but I dont know man seems shady as my previous idea was to shady for me to actually go through with . Step 2 - Remove side cover. Have a look at the clutch plates so you've got an idea of how it goes back together. You might be used to adjusting your Harley Davidson clutch but mileage and riding style can demand further work. Figure 13. It is not that hard to hold the hub. Slowly release the pressure off the diaphragm spring and pull the clutch disks from the clutch basket. ), then attatch that sum-bitch to the frame and your all set. without any fear of damage to your expensive clutch basket. Used to hold the inner clutch hub, which is necessary for removal and installation of the clutch hub and clutch basket. Chamfer the holes to eliminate any burrs and reinstall the plate when you are finished. Start by pulling the smaller circlip around the inner hub. DON 06 450r 67/42 ($$ pit) (Red) * As for the rag, or ally in gears trick, that's all good, i've used it on the crank gears to undo the flywheel and primary drive nut before, but i've never seen a gearbox you can access without splitting cases? the clutch cover transfers the load from basket to clutch plates. Clutch cover and basket removal. Step 3: Secure The Two Pieces With The Bolt, Nut And Washers Step 4: Make Sure The Two Pieces Move Smoothly From 90 To Close. If the nut is super tight and will not come off you can heat it up alittle to loosen the loc-tite nd the nut will spin off. Replaces HD tool #HD-91042, Used on 1984 and later 1340cc . Install the re-built clutch pack and tighten to 125 ft lbs. clutch hub and basket holding tool. 11- Remove the nut, washer and basket from the mainshaft. The tools can even be extended to create more leverage if required with any simple workshop tool, or simple tube but the tools themselves are an . This keeps the Hub locked to the basket. Remove the clutch pressure plate springs, loosen all first, then remove . This process and removing and installing the clutch can take some mechanical know-how and tools, but it isn't much more than a two-hour job with the excellent, included instructions.Another bonus . You might be able to get by with the same tools you use on the GL1000s. I offered (stupidly) to restore a friends PK50 for her a couple of years ago. Modify the screw head to create a screwdriver slot. Fits clutch plate exactly. Flywheel Pulley Holder 330mm/13in Motorcycle ATV Clutch Flywheel Holding Tool Clutch Hub Basket Gear Holder Tool. Thanks in advance. The tools can even be extended to create more leverage if required with any simple workshop tool, or simple tube but the tools . CDZWJ Motorcycle 20mm 24mm Lock Nut Removal Tool Clutch Remover 4-Pin Spanner Socket Wrench fits for Honda 50cc-125cc ATV Dirt Bike go kart. About Press Copyright Contact us Creators Advertise Developers Terms Privacy Policy & Safety How YouTube works Test new features Press Copyright Contact us Creators . $15.99 $ 15. This Lowbrow Customs Video Covers: - Disassembly. I've heard stories of sitting a penny between the basket gear and crank to jam it, putting it in gear with someone sitting on the bike pressing the rear brake to finally a metal bar through the rear sprocket locking against the swing arm!!!! Remember, each friction plate is separated by a plain plate. All you need is some flat stock, a couple of bolts to go into the clutches and a center bolt to push against the crank shaft. Location:: Hertfordshire. I actually bought one of these tools . All you need is a leash (or belt of some sort that you can wind in the basket. UK Made by EBC, laser cut tools for clutch removal, loosening of drive shaft bolts & re-tightening easy. In this video I explain how to make your own diy clutch holding tool to remove clutch basket by using one clutch disk with two 1/4 X 20 holes drilled, 4 nuts attached to a steel bar as a lever. And the clutch is very easy to work on. Ships Fast. 99. the proper specialty tools. The clutch cover is on the right side of the engine, and most covers have about 5 bolts holding it on (This bike is an '01 Honda CR125). Open the derby cover so you can see the primary oil level. SPECIAL TOOL REQUIREMENTS . Now select shims to create .001-.010" of clearance between the .207" washer and inner primary bearing race. To remove the Transmission Main Shaft Nut (in the Clutch Hub), you need to remove the Clutch Release Assembly while the Clutch is still assembled. It doesn't take much to free the two and often times the hub will fall out once it's started, so be careful. If you press the center button in it will release the PTO clutch and you will be able to turn the PTO body to align the setscrew holes with the cut out in the "star" on the pulley. It is supposed to smooth out the clutch by reducing the amount of travel the clutch shell can move in and out on the hub. I bought a cylinder kit and new primaries but got stuck when it came to removing the clutch basket. Tightening the nut on the clutch hub requires a special tool for holding the hub but it is possible to do it without a tool: This obviously only work with engine still in the frame, - Put gearbox in last gear, 5th or 6th reducing the torque on the chain - Put a steel bar through the swingarm searching for a position that relies on holes on sprocket and brake disk, NOT on the spokes. Then i made a tool that holds the pressure plate so that the . there should be a hole in teh side that lines up with the primary bolt, you need to unscrew that bolt, then insert a special clutch tool and tighten it, and it pops the clutch off the crank. 27. . Next, reinstall the pressure plate, the springs and the bolts, taking note of any alignment marks that may be present. NovaKaw650 Super Moderator Joined Sep 26, 2004 12,656 Posts Not recommended for v-groove or half round style clutch hubs. break one of those posts and the clutch hub is junk. I do realize I misread my tape measure once in video once in video Remove snap ring from the pivot pin of the clutch lever and pull pin out. Save Share. How to remove primary clutch from atv no special tools. Instead, a diaphragm spring retainer is used that bolts to the diaphragm spring for even pressure. Lux you are correct my friend #5 does not go back in. Simply remove that snap ring and the adjuster plate. I though about putting a piece of flat stock steel between a couple of the studs were the bolts go for the pressure plate, but with my luck, the studs would snap off. Stack them in the order they come out, including the judder spring and washer which are the last parts to come out of the clutch basket. How to REPLACE a clutch in a car - (Step by Step guide) How to Turn a Book into a Clutch how to remove a clutch basket without tool [very easy] How to Remove Transmission Replace the Clutch on a Honda . Clutch Replacement: Removal How to remove a clutch without the tool. When you put the crank nut back on, there is an updated torque spec for it higher then what is in your manual. Jun 17, 2020. EBC Clutch Installation and removal tools. Normally no need to replace the clutch cover gasket. . Grip the screw head tightly using mole grips or similar. 5.0 out of 5 stars 3 . Replace the outer face and reinstall your retaining clip, then remove compression tool. $18. How to Remove STX125 Motorcycle Clutch Basket Nut - Clutch Holder Center Nut - DIY clutch holding However, if the clutch basket needs replacement, the engine will need to be removed from the motorcycle. With the Cover removed, you can now start the procedure to remove the clutch basket. Step 5: Use The Existing Clutch Spring Retaining Bolts To Secure The Tool to The Clutch Inner That was an easy way to save a . Just hold the clutch hub with your hands and let the impact take the nut off. New Without Packaging. Go purchase a couple of spares as well as a little larger bolt for pushing against the crank shaft along with a couple of cheap taps. Drain as much of the primary oil as possible before starting. slacken off handlebar lever adjuster fully. Replace clutch on big truck. 10. or sign . Figure 1. No matter what area of your bike needs working on -- from the wheels to the clutch to the brakes to the drivetrain -- it probably requires a special tool that you're never going to find at Home Depot! So i decided to remove the clutch for inspection. Starter nose mounting screws. Once you're all set up and have the proper tools, it's time to take the clutch off the bike. My clutch lever is properly adjusted. A puller is not necessary to remove the hub from a tapered shaft.. loosen the nut about 2 turns, remove the clutch pushrod, now, rap the nut solidly with a 32oz or larger hammer, the hub will pop off from the vibrations. You can make a tool by drilling a couple of holes in one of your clutch plates and bolting a sturdy "L" bracket to the plate. In. The original is indestructable. #4. Removing the Clutch basket is the only way to get to a tricky Starter Bolt. Keep the stack together and put them within easy reach. Remove the clutch lifter rod and bearing. Place your catch pan under the primary and remove the drain plug. - Inspection. in this video, I show you how to make up a quick diy clutch holder toolIchiban Moto links: tee shirts: https://teespring.com/stores/ichiban-motoI am somewhat. Put a couple of nuts in between the plate and the bracket to allow the plate to be positioned below the edge of the basket. $28.95. Rekluse is a great product but if this is your first dirt bike take it out and feel whats it is like to ride without it. Notice: its obviously going to be alot harder if the. . First check the cable adjustment. I removed the cover and as much of the gasket material as possible by hand. If you're installing a Rekluse Z-clutch, there are directions that come with that. You don't have to take apart the clutch, just remove the whole clutch assembly and stator cup and primary chain all together as a unit. I've decided it's time I finished it but I need advice on removing the clutch basket. Post by eddbmxdude onFeb 17, 2014 at 4:53am. Step 3: Remove all bolts holding down your old clutch pulley using a socket wrench. If you see of feel like anything is bending/stressing too much, stop, back off, spray, sit and try again. . Now i have come to a deadend, i havent been able to remove the 50mm big nut that holds the diapgrahm springs. EBC Clutch Basket Removal Tool CT003 Suzuki RM125 1992 - 2011 . After the clutch center pressure plate and hardware is removed the clutch fiber disks and steel disks can be removed from the clutch basket. There are basically 3 options to consider when you need to remove these security screws: Use a special Clutch Head Removal Tool. In the back of the star is a pin that sits inside the shaft located directly behind it. Push a 20- to 24-inch length of rope down into the engine cylinder spark plug hole to act as a soft piston stop to allow the engine spanner clutch to be removed. Free shipping Free shipping Free shipping. What's the best way to remove the clutch basket without the holding tool. So I did to my T what I do to my dirt bikes, put in Barnett springs with a 45/1000 thick washer. Im showin you guys that want to save some money on tools on how too take a clutch basket off a dirtbike engine without buying the special tool for it Frank has rebuilt countless transmissions and the novice or experienced rebuilder can follow along with this video. That also is an easy job. Drain your primary completely. There is a fourth option - which would be to use a drill to drill-out the security screw. It should only take a little pressure and maybe a few light taps with a brass hammer to get the basket to budge and pop off. Tighten the locknut. Spatten1 Gently clamp the clutch basket with a clutch basket tool to hold it in place and use a heavy duty impact gun with a 27mm socket to remove the nut in the center of the basket. If you ever get into doing clutch repairs on the GL1100, most clutch repairs can be performed without engine removal. 11. 5.0 out of 5 stars 3. Lots of noise over nothing.

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