Removing clutch hub bolt

john6r · Post by **john6r** » Wed Aug 16, 2006 5:33 pm

I'm currently trying to split the engine to get into the gearbox. Has anyone got a tip to remove this bolt holding the clutch hub

. I have tried with a rattle gun but cant stop the actual hub moving with the bolt! I would appreciate any help that saves me spending $1000s with a dealership

. The engine is a 99 9r.

Cheers.

ozx6r · Post by **ozx6r** » Wed Aug 16, 2006 6:10 pm

as advised by whales kawasaki and worked for me

put friction plates back in and press against them with your hand and then use a rattle gun - i only applied little pressure with my thumb and it was enough to hold it

good luck

MickLC · Post by **MickLC** » Thu Aug 17, 2006 9:11 am

Hmmm a 99 ZX9R and you are splitting the cases to get to the gearbox. Have you read this? http://www.ksrc-au.com/html/fixing_a_zx9r_gearbox.html

As far as getting the nut undone, there is a special tool which looks like a set of mutant vice grips which you are meant to use to hold the clutch basket while you get the rattle gun onto the nut (see below). Of course nobody has a set of these lying around, so we just knocked up a brace with the some steel and a MIG.

All it needs to do is fit into the slots on the outside of the basket strongly enough to stop it rotating, but still allow enough room to get the socket etc into the nut.

HTH

FrogZ · Post by **FrogZ** » Thu Aug 17, 2006 3:47 pm

I use an old plate with a handle (bolt) welded on it
Its like the Ducati tool, I just didnt have to get a bank loan to buy it

Its for a Darmah but a clutch is a clutch

mick_dundee · Post by **mick_dundee** » Thu Aug 17, 2006 6:25 pm

Screwdriver will stop the plate spiinning, just brace it against the crankcase.

john6r · Post by **john6r** » Thu Aug 17, 2006 6:41 pm

Thankyou to everyone. A mechanic a Repco had a go prior to my post. He used a pry bar wedge between the grooves but this did not work. I was also worried about damaging the clutch basket. I will go back with your suggestions and let you know how it goes and which method works best

. Thanks again.

ozx6r · Post by **ozx6r** » Thu Aug 17, 2006 6:51 pm

try mine no tools involved

i was worried it sounded dodgie but it really works

john6r · Post by **john6r** » Sat Aug 19, 2006 12:01 pm

great! Its so simple as ozx6r said put the plates back in. Now let's see how the rest goes.

In general if I find that gears/dogs are worn would it be best to get a second hand box or new parts, bearing in mind the year of my bike and the condition other gearboxes are probably in.

thanks

MickLC · Post by **MickLC** » Sat Aug 19, 2006 2:28 pm

Bugger! I wish someone had told me about the clutch plate trick

Glad it worked anyway

FrogZ · Post by **FrogZ** » Sat Aug 19, 2006 3:54 pm

Ditto...