T500 Clutch Drum and Sprocket Removal

[keithwwalker]

The EBC clutch tools for the T500 models are:

T 500 1/2/3 (18 ears) 68-70 CT046
T 500 R/J/K/L/M (12 ears) 71-75 CT022

You can get on evil bay or amazonz for about $20

[oldjapanesebikes]

Or you can use the "Coyote Maneuver" - use a rag !

[Pete O'Dell]

bolt 2 scrap fibres and a steel together, costs sod all, I used a 3/8 air gun with no holding tool too undo and do up, never had one come undone yet

[keithwwalker]

Pete, that is probably the best solution! btw, the EBC site may be wrong, my 72' T500 has an 18 ear clutch basket; and while the 12 ear tool is available, the 18 ear is not readily available.

bolt 2 scrap fibres and a steel together, costs sod all, I used a 3/8 air gun with no holding tool too undo and do up, never had one come undone yet

[rbond]

My GT500 has a 18 tooth basket. I was going to replace the plates, looked very hard to get the 12 tooth 'correct' EBC plates. Went to install them and 18 teeth instead of 12, WTHeck? Put the new springs in, re-assembled with the original plates and hit e-bay for an 12 tooth basket. Waiting for when I pull the engine for a overhaul to put in the 'correct' 12 tooth basket and new plates.......

[keithwwalker]

Wouldn't you know, after I installed my Nova T500 clutch basket, both the EBC tools didn't fit(!).
The Nova clutch uses CRF450 friction plates (outer tab) and a combo of the T500/DR350 steel plates for the inner plates.

That would be CT009 for the friction outer ears, but CT022 for the inners. The CT022 has the right number of outer ears, but they are too big, grrr

I ended using the MotionPro gear jammer tool (its got a magnet to keep it in place, when on the gears) and stomping on the rear brake to get good torque on the clutch basket. You have to be a double jointed acrobat to do it alone, but it can be done!

https://www.motionpro.com/motorcycle/partno/08-0427/



Nice thing about the Nova clutch basket conversion is that the CRF450 friction plates are metal backed, and not fiber like the NOS.

[Suzukidave]

That Motion Pro tool is nice , i havent seen one of those before

[desmocat]

I've always used the rag and electric impact wrench, always has worked for me on street and road race T500's

[tz375]

If you have a damaged gear with the same tooth spacing as the clutch sprocket, just cut off 3 or 4 teeth in a small segment and use that.

[keithwwalker]

If you have a damaged gear with the same tooth spacing as the clutch sprocket, just cut off 3 or 4 teeth in a small segment and use that.

Great hint, I was about to throw an old chattered clutch out, glad I didn't.

btw, I spoke with EBC and they referred my to the guy how laser cuts their clutch tools. He made a custom wrench for me that will fit the Nova clutch.
Now isn't that cool!

[yeadon_m]

The soft rag between primary pinion and clutch outer just worked to release my 550 pinion, which was torqued to 102 lb ft, astonishingly. Check it out. The earlier ones had a lock washer and 40 lb ft but were inclined to shake loose and get noisy, so Suzuki went to a sprung steel domed washer and a helluva lot more torque.
Mike

[keithwwalker]

I have to admit, that the rag in between the primary and the clutch gear, will work every time, but damn, those EBC wrenches are slick!
Here's my special wrench for the Nova Racing billet clutch basket.

[rngdng]

There is another way to hold the inner clutch....it's a little odd, but that's me. Put tranny in gear, any gear. Use the old chain and wrap it around the CS sprocket. Pinch the ends of the chain (as close to sprocket as possible) with vise grips forming a wrench. Hold "wrench", use air wrench on clutch nut. It does put stress on the entire tranny but if it can't take that, it will fail later anyway.


Lane