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Main Area => General GS500 Discussion => Topic started by: goat on July 04, 2004, 03:27:53 PM

Title: Tips for removing the clutch?
Post by: goat on July 04, 2004, 03:27:53 PM
I am going to need to remove the clutch on my engine and I am looking for tips on how to hold the thing still so I can get the nut off.

The engine is out of the frame. There is a tip in my haynes manual, but I do not understand what they suggest doing.

Thanks in advance for the suggestions.
Title: Tips for removing the clutch?
Post by: aplitz on July 04, 2004, 07:49:00 PM
I just put it in gear and held the brake, but that probably won't help you.  If you have access to a welder, you an make a tool out of a steel clutch plate.  An impact wrench should also work, just be careful.
Title: Tips for removing the clutch?
Post by: Blueknyt on July 04, 2004, 09:10:01 PM
i made a tool from old clutch plates, 3 metal and 2 fiber, drilled 2 holes through them at 180 degrees apart, while still in basket lined up.  put small bolts through them and it locks the inner and outer baskets wonderfully,  then place a penny between the crank and clutchbasket gears and loosen the nut, you can tighten it the same way.
Title: Tips for removing the clutch?
Post by: Kerry on July 04, 2004, 10:18:32 PM
Quote from: Blueknyti made a tool from old clutch plates
Do you have way to take / post pics?  I think I get what you're saying, but I'd LOVE to see a 2-4 shot sequence.... :roll:
Title: Tips for removing the clutch?
Post by: Blueknyt on July 04, 2004, 10:48:15 PM
No, i wish i did, then i would be doing the "engine rebuild" writeup.  i have a few old clutch baskets and shafts, i used some old clutch plates, set the shaft in the vice (it was a bad shaft) assembled the clutch basket on the shaft, laid 5 clutch plates inside like noral, and drilled 2 holes through all 5 plates at 12 o clock and 6 o clock, 2 small bolts with nuts binding the plates in one mass, and presto. one GS clutch tool. locks inner hub and outer basket perfectly, keeping the stresses on the slots and splines where they belong.
Title: Tips for removing the clutch?
Post by: Bob Broussard on July 04, 2004, 11:06:39 PM
You can take a pair of visegrip pliers and clamp them on the edge of a steel plate. Slide the plate on the inner hub with the pliers in a slot on the outer hub. The penny in the teeth of the gears is a great way to stop the basket from turning.
The nut will come loose easier than you expect. Tightening torque is 40 ft lbs.

I did this method many times. I finally took some small angle iron pieces and welded them on a steel plate to make a tool.
If the piston is off the rod, you can use a ratchet extension through the rod end against the cases to stop rotation.
Title: Tips for removing the clutch?
Post by: sledge on July 05, 2004, 01:24:39 AM
Take a penny or other copper based coin and jam it inbetween the primary crank gear and the gear cut around the clutch basket.......it never fails and more importantly wont damage the teeth.