SuzukiSavage.com - Torque Clutch Springs Bolts?

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: Torque Clutch Springs Bolts? Reply #30 - 05/13/20 at 10:25:03 philthymike wrote on 05/13/20 at 10:18:41: I almost went over sideways trying to tighten the big nut while applying the rear brake. Been there, done that, learned a better way. put a ratchet strap around the OD of the wheel to the frame. tighten down the strap and that wheel ain't going nowhere.
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philthymike

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Re: Torque Clutch Springs Bolts?
Reply #31 - 05/13/20 at 10:34:05

verslagen1 wrote on 05/13/20 at 10:25:03:

philthymike wrote on 05/13/20 at 10:18:41:

I almost went over sideways trying to tighten the big nut while applying the rear brake.

Been there, done that, learned a better way.
put a ratchet strap around the OD of the wheel to the frame.
tighten down the strap and that wheel ain't going nowhere.

Funny part here is a just recently used a ratchet strap to open a can of PVC pipe joint cement and put the thing away without it even dawning on me that I could have tried it on the bike. Doh, stupid brain!

Cheesy

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Torque Clutch Springs Bolts? Reply #32 - 05/13/20 at 11:59:06 Against advice in the manual, Ive never messed with the clutch that I didnt use my IR 1/2" drive impact,, And never had a problem,,
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badwolf Serious Thumper Offline Ridin' my Lil' Bagger - 153k miles so far Posts: 804 Palm Beach County, FL Gender:	Re: Torque Clutch Springs Bolts? Reply #33 - 05/13/20 at 13:55:14 I also use my impact wrench, and a rag jammed into the primary gears. works!
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Torque Clutch Springs Bolts? Reply #34 - 05/13/20 at 16:07:10 I use a chuck of leather in the gears, but,, whatever,, A penny just might not be the best answer..
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philthymike

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Re: Torque Clutch Springs Bolts?
Reply #35 - 05/15/20 at 07:12:29

Well I have the special tool now so I guess I'm a big wimp compared to all these other manly-man, bubby-rigged and half-assed solutions. Shame on me for wanting to use the right tools for the job.

Remaining backordered parts came in yesterday and in time for the weekend. Let's see if I can manage to do it right this time around without busting crap like a clutz.
Itching like mad to get out riding....

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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philthymike

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Re: Torque Clutch Springs Bolts?
Reply #36 - 05/16/20 at 10:50:33

Clutch all put back together and cable adjusted. Working good now.
Have to get used to the heavier pull from Barnett Springs.
Finally have the powder coated clutch cover installed.
Need to go bed in my new pads and rotors now.

That fancy tool was useless. Couldn't fit the socket through the hole in the middle. Of all the dumb stupid things....
Back to the store with it!

Note: Vertex gaskets do not have the sealant applied. You gotta diy

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Torque Clutch Springs Bolts? Reply #37 - 05/16/20 at 11:10:05 Bummer that your best efforts to do it right were thwarted. So, which manly-man, bubby-rigged and half-assed solution did you wind up goin with?
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Torque Clutch Springs Bolts? Reply #38 - 05/16/20 at 11:30:21 justin_o_guy2 wrote on 05/16/20 at 11:10:05: Bummer that your best efforts to do it right were thwarted. So, which manly-man, bubby-rigged and half-assed solution did you wind up goin with? Put the old lady on the bike to push the brake pedal
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Torque Clutch Springs Bolts? Reply #39 - 05/16/20 at 11:51:05 I wonder how much concern I could have avoided had I only asker her to stepon that pedal... Smart move,,
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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1452	Re: Torque Clutch Springs Bolts? Reply #40 - 05/16/20 at 12:41:05 If you want to send me the tool and the socket, I can either skim the socket or open up the hole in the tool, or both. Was it an impact socket? Those are usually more full figured.
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Torque Clutch Springs Bolts? Reply #41 - 05/16/20 at 12:52:39 NO MORE STINKING CLUTCH SLIPPAGE!!!!! HALLEFREAKINLUJAH!!!-
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Re: Torque Clutch Springs Bolts?
Reply #42 - 05/20/20 at 11:23:34

Hey hey,
Got the package today. Turned the clutch plate over, found the biggest transfer punch that would fit in the hole (thru holes, not blind), gave each broken bolt a center dimple, and drilled them from the back with a standard drill bit. Once the bit caught, the broken bolt started to unscrew, Grabbed it with a vise grip and unscrewed the rest of the way.
Chased the holes with a 6x1 tap in case the threads were unhappy.
All told, about 10 minutes.
So, what size socket were you using on the clutch nut? Not enough metal to open up in the clutch tool Have to turn down a socket.

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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4406 Honolulu	Re: Torque Clutch Springs Bolts? Reply #43 - 05/20/20 at 12:45:17 Sweet job Armen. Very cool method you used. Man, would you look at the stretch in those threads. You think Mike got em tight enough?
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philthymike

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Re: Torque Clutch Springs Bolts?
Reply #44 - 05/20/20 at 15:36:27

Armen wrote on 05/20/20 at 11:23:34:

Hey hey,
Got the package today. Turned the clutch plate over, found the biggest transfer punch that would fit in the hole (thru holes, not blind), gave each broken bolt a center dimple, and drilled them from the back with a standard drill bit. Once the bit caught, the broken bolt started to unscrew, Grabbed it with a vise grip and unscrewed the rest of the way.
Chased the holes with a 6x1 tap in case the threads were unhappy.
All told, about 10 minutes.
So, what size socket were you using on the clutch nut? Not enough metal to open up in the clutch tool Have to turn down a socket.

My Hero! Dang dude I'm at a loss for words. 10 minutes? Jumping Jesus on a pogo stick!

I think the socket was 32 mm.
You can see in the picture how bad it is.

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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