clutch cover removal tips

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jabcb
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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

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joethebike
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Re: clutch cover removal tips

Post by joethebike »

Do a 200% check thar all screws are out.
1972 Suzuki T350 160,000km +2 Castrol 6 Hour races
1982 Honda CX500 EC 272,700km
2005 Suzuki DL650 145,000km
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jabcb
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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
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tz375
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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.
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FullMoon
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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
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jabcb
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Joined: Mon Dec 13, 2010 4:32 pm
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Suzuki 2-Strokes: 69 T350 thru 75 GT750
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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
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