clutch cover removal tips

Need some help? Put your question up here. Many years of experience on the board to help you get up and running.

Moderators: H2RICK, diamondj, Suzsmokeyallan, oldjapanesebikes

Post Reply
User avatar
jabcb
Moto GP
Posts: 4111
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

clutch cover removal tips

Post by jabcb »

Sealant + gasket was used. 100% sure all the screws are out. Pounding with a rubber mallet has not freed the cover.

Question: is there a slide hammer tool for blind holes that would work on the M6 cover screw holes?

Any other tips?
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
joethebike
Around the block
Posts: 62
Joined: Mon May 23, 2011 4:23 am
Country: Australia
Suzuki 2-Strokes: Suzuki T20-250-350-500, DL650
Location: Maleny, Queensland, Australia

Re: clutch cover removal tips

Post by joethebike »

Do a 200% check thar all screws are out.
User avatar
jabcb
Moto GP
Posts: 4111
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: clutch cover removal tips

Post by jabcb »

Already 300% checked. Removed all the screws. Using a mirror, checked entire parameter for only holes without screws. Counted the number of removed screws.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
User avatar
tz375
Moto GP
Posts: 6198
Joined: Mon Nov 03, 2008 10:47 am
Location: Illinois

Re: clutch cover removal tips

Post by tz375 »

Silly question perhaps but did you remove the clutch actuating rod adjusting nut and lock nut?

If so there are two dowel pins that locate the cover and may be tight.
If all else fails use a small flat plate with three 5mm holes to hold onto the cover and one large threaded hole for a bolt to push the cover off but it should come off with very light hand pressure on the wrench on that center bolt which will press against the clutch actuating rod.
User avatar
FullMoon
On the street
Posts: 17
Joined: Thu Jan 18, 2018 1:21 pm
Country: United States
Suzuki 2-Strokes: '74 GT380
Location: Lincoln, Nebraska

Re: clutch cover removal tips

Post by FullMoon »

I find one of the most useful tools in my arsenal is a heat gun.
Perhaps a bit of warming would help the sealant relax its grip.

Mitch
User avatar
jabcb
Moto GP
Posts: 4111
Joined: Mon Dec 13, 2010 4:32 pm
Country: USA
Suzuki 2-Strokes: 69 T350 thru 75 GT750
Location: southwestern Pennsylvania

Re: clutch cover removal tips

Post by jabcb »

Problem solved.

The cover & crankcase match nicely on the top, as one would expect. But on the bottom where nobody looks, there is a bit of a lip. A modest lateral tap with a rubber mallet & junk screwdriver freed the cover.

I had tried heat after reading FullMoon's post but it still didn't budge. Was moving the motor some hours later & noticed the lip on the underside.
So perhaps it was the combo of heat & modest lateral tap.

Thanks, for the tips.
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 & 75
GT380 72
T500 69 project & 73 project
T350 69 & 71
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE
Post Reply