Examine the shift ratchet, primary drive gears, and everything else you can see with the cover off. 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. 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. Next I removed the clutch cable and foot shift lever, and loosened the bolts on the cover. We have the best prices on Bad Boy Parts Online! Replace clutch on big truck. Reinstall your pushrod, retainer marked "OUT' on the side that faces out and your adjustment screw and nut. We carry only the finest quality specialty tools from top manufacturers like BikeMaster, Pit Posse Motorsports, Motion Pro, JIMS, and more. Strong zinc-plated carbon steel. 99. . I bought a cylinder kit and new primaries but got stuck when it came to removing the clutch basket. Step 1 - Drain your primary. ! 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. 8mm spanner pins on the back can also be used to hold flywheels, sprockets, gears, etc. slacken off handlebar lever adjuster fully. All you need is your Bad Boy Serial Number to find all of the diagrams for your unit. Remember, each friction plate is separated by a plain plate. 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. 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. Chamfer the holes to eliminate any burrs and reinstall the plate when you are finished. Keep the stack together and put them within easy reach. 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. The other tool which might work is a . Next with chisel and hammer, make a detent on the clutch hub nut. 7 Those dark grey indents are where the friction plates' location lugs whack into the clutch basket. The penny is soft enough that it will bend before any possible damage could be done to other parts. Lux you are correct my friend #5 does not go back in. Remove the clutch lifter rod and bearing. DON 06 450r 67/42 ($$ pit) (Red) * Secures clutch basket in order to remove clutch retaining bolt. 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. Jun 2, 2003. $28.95. 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. 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. 11. Remove snap ring from the pivot pin of the clutch lever and pull pin out. I offered (stupidly) to restore a friends PK50 for her a couple of years ago. It also works when the clutch "grabs" when you are sitting with the clutch pulled in. And yes, you do need to remove the snap rings. Expertly crafted from the highest grade . Next, reinstall the pressure plate, the springs and the bolts, taking note of any alignment marks that may be present. Unscrew the spanner clutch drum . Now i have come to a deadend, i havent been able to remove the 50mm big nut that holds the diapgrahm springs. Flywheel Pulley Holder 330mm/13in Motorcycle ATV Clutch Flywheel Holding Tool Clutch Hub Basket Gear Holder Tool. However, if the clutch basket needs replacement, the engine will need to be removed from the motorcycle. Replaces HD tool #HD-91042, Used on 1984 and later 1340cc . If . Step 4 - Remove the starter "nose". What's the best way to remove the clutch basket without the holding tool. 4.3 out of 5 stars 246. Modify the screw head to create a screwdriver slot. This Lowbrow Customs Video Covers: - Disassembly. To my pleasant surprise, this technique works GREAT!!!! Step 2: Now remove all of the screws from both sides of your compressor case cover and then gently lift upon it. EBC - CT003 - Clutch Removal Tool Suzuki RM 125. The keyway does not hold the clutch on, the taper does, it produces an interference press fit, and the bond is easily broken. 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). - Shifter Fork Alignment. Jun 17, 2020. You might be used to adjusting your Harley Davidson clutch but mileage and riding style can demand further work. $8.27 $ 8. Learn helpful tips in this video. The tools can even be extended to create more leverage if required with any simple workshop tool, or simple tube but the tools . EBC Clutch Installation and removal tools. or sign . With the starter now out and on your bench, remove the front cover on the left end of the starter (as mounted). Ships Fast. Figure 1. Remove the starter to get the hook around the ring gear on the top and don't overdo it. I do realize I misread my tape measure once in video once in video Free shipping Free shipping Free shipping. About Press Copyright Contact us Creators Advertise Developers Terms Privacy Policy & Safety How YouTube works Test new features Press Copyright Contact us Creators . Continue with Facebook. Normally no need to replace the clutch cover gasket. I actually bought one of these tools . Then i made a tool that holds the pressure plate so that the . Good video. It doesn't take much to free the two and often times the hub will fall out once it's started, so be careful. Thanks in advance. Frank has rebuilt countless transmissions and the novice or experienced rebuilder can follow along with this video. . Step 1: Cut The Angle Iron At 1/3 Length. That also is an easy job. $26.99 $ 26. 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. Make sure the retaining clip is completely seated in the slots in the little fingers. Step 2: Align The End Of The Angle Iron Pieces. Remove clutch lever from bracket and pull anchor pin from cable. The first place to do the adjustment is inside the black cover at the back of the engine. 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 . Repeat Steps 8, 9 and 10 to achieve .001-.010" clearance with . Hello, you may be able to sneak it out without removing the clutch basket. Step 4: Once removed, carefully disconnect wires from the old clutch pulley using a wire connector. Not recommended for v-groove or half round style clutch hubs. Install the re-built clutch pack and tighten to 125 ft lbs. Lots of noise over nothing. . At the advice of a local Norton shop, I did the following to the bike which quickly (and cheaply) remedied the trouble: . 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. 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. NovaKaw650 Super Moderator Joined Sep 26, 2004 12,656 Posts Grip the screw head tightly using mole grips or similar. 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!!!! Reply #5 on: September 19, 2015, 11:21:30 pm . So I did to my T what I do to my dirt bikes, put in Barnett springs with a 45/1000 thick washer. In the back of the star is a pin that sits inside the shaft located directly behind it. Speeds clutch removal. My clutch was slipping for the past year and a half (in 5th and lately in 4th when hard on the gas). Here's a clear view of the Clutch Hub without the basket or any Clutch plates in the way. 27. . This keeps the Hub locked to the basket. Replace the outer face and reinstall your retaining clip, then remove compression tool. Remove the clutch actuator rod from the primary cover. 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. 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. EBC Clutch Basket Removal Tool CT003 Suzuki RM125 1992 - 2011 . 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! The bolt holes in the clutch are the same threads as the clutch cover. First fit the damper spring SEAT - This is the slightly thicker of the . Do not attempt to install the S&S clutch without . CT Series Clutch Removal Tool by EBC. Location:: Hertfordshire. . (Figure 14) Remove two T-27 Torx screws with washers from clutch bracket. 99. 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 Recommended for square tooth style clutch hubs. Aids in unlocking clutch retainer bolts. Place your catch pan under the primary and remove the drain plug. You will need a jam nut tool, and a spider holder AFAIK (as far as i know). Adjustable jaws open up to 5 inches wide and are recommended for square tooth style clutch hubs. Step 2 - Remove side cover. Fits clutch plate exactly. 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 . 11- Remove the nut, washer and basket from the mainshaft. After pulling that clutch assembly off, simply give it as is to someone you dont like. I've decided it's time I finished it but I need advice on removing the clutch basket. 10. Mark it and put it back in the same holes it came out of. Only use a heavy duty impact gun. You will probably need an impact wrench to do . Instead, a diaphragm spring retainer is used that bolts to the diaphragm spring for even pressure. Spatten1 What tools do I need to remove the clutch basket? Do not attempt to break this nut loose with a breaker bar, you will likely damage the clutch basket with the basket tool. If you're installing a Rekluse Z-clutch, there are directions that come with that. Drain your primary completely. First check the cable adjustment. 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. Features 8mm spanner pins. Figure 13. Removing the Clutch Basket Norton 961 1 | P a g e r i c h a r d @ c o o t e 1 . Jaws open up to 5 inches wide. Drain as much of the primary oil as possible before starting. Step 3: Remove all bolts holding down your old clutch pulley using a socket wrench. $15.99 $ 15. It's two "big freaking nuts", one of which is reverse threaded, but not a big deal. Yesland 2 Pack Spanner Wrench, Adjustable Wrench Holder, Clutch Hub Rotor Sprocket Spanner Wrench Set & Fan Clutch Removal Tool Accessories for Scooter, Motorcycle. After the clutch center pressure plate and hardware is removed the clutch fiber disks and steel disks can be removed from the clutch basket. EBC CT003 Clutch Removal Tool. Save Share. Just hold the clutch hub with your hands and let the impact take the nut off. ), then attatch that sum-bitch to the frame and your all set. Open the derby cover so you can see the primary oil level. My clutch lever is properly adjusted. Newer models (2013-present) do not use a snap ring. Hey guys can anyone tell me a trick for removing the clutch hub nut. Remove the lockplate from the rear of the basket, then take the clutch to the press and separate the hub and the basket. 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. 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. If your just replacing shift forks the clutch assembly can stay on the transmission shaft. After you get the cover off, you'll be able to see the basket/plates. UK Made by EBC, laser cut tools for clutch removal, loosening of drive shaft bolts & re-tightening easy. How to remove primary clutch from atv no special tools. 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 . 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. So i decided to remove the clutch for inspection. Transmission cover before removal. 6 Pull the old plates out in one go. It is not that hard to hold the hub. (part 1) Remove shifter, free up top of trans. You might be able to get by with the same tools you use on the GL1000s. Flywheel Pulley Holder 330mm/13in Motorcycle ATV Clutch Flywheel Holding Tool Clutch Hub Basket Gear Holder Tool. Aids in unlocking clutch retainer bolts. If you see of feel like anything is bending/stressing too much, stop, back off, spray, sit and try again. Any idea how it broke? Start by pulling the smaller circlip around the inner hub. I removed the cover and as much of the gasket material as possible by hand. Have a look at the clutch plates so you've got an idea of how it goes back together. 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. Use a Torx driver and bit to remove the four Torx bolts on the derby cover. - Inspection. 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. 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. . 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. Re-install the shift shaft in its hole in the crankcase aligning the dogs on the star. 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. Removing the Clutch basket is the only way to get to a tricky Starter Bolt. Clutch Replacement: Removal How to remove a clutch without the tool. Notice: its obviously going to be alot harder if the. clutch hub and basket holding tool. 5.0 out of 5 stars 3. First i tried by putting the bike in 1st gear and apllying the rear brake, no succes. Re: Clutch tool. New Without Packaging. Slowly release the pressure off the diaphragm spring and pull the clutch disks from the clutch basket. With the Cover removed, you can now start the procedure to remove the clutch basket. 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. Clutch cable and shift lever removed, transmission cover removed. Frank also shows the proper method to reinstall the transmission into the frame with proper shimming and alignment. Apr 22, 2009. 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. the proper specialty tools. Cost for the new bolts (grade 8 ) plus a total of 10 washers $4.30 (threw the stock bolts and washers away) If you have to remove the basket just be careful how you wedge it to get the nut off. SPECIAL TOOL REQUIREMENTS . #4. All you need is a leash (or belt of some sort that you can wind in the basket.
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