cant get clutch off 1996 blaster

[BigRat71]

I cant get the clutch boss (Bolt) off... its on really really tight any ideas how to get it off? or anything i need to do befor that can come off? its the big bolt in the middle of the clutch basket i already took off all the plates. do i need to take of that washer behind the bolt first? any help would be great!

 

[Surfrjag]

the washer is a lock washer you should have just bent it off the nut. get an impact and or a clutch holding tool. if you have the clutch holding tool you can use a breaker bar and get it off.

 

[BigRat71]

so straiten the lock washer first? and what should i do it i dont have a clutch holder?

 

[burn400]

what I had to do was put a strap on the bumper to the axle and ratchet it down to be compressed. The stick a little prybar I had through the sprocket and roll it till it caught and was wedged. That allowed me to get the nut off after bending the washer off of it.
To put it back on was a little trickier as you need to tighten to spec which is 58lb ft and there isnt much room to turn a torque wrench like mine. So I put it up on its ass end and was able to start at the upper a arm and hit 58 before I hit the lower. I suggest you borrow an impact wrench But if you can't...that's how I just did it.

 

[EZRider76]

Forget that ^^^^ advice...take the time to order the clutch holder thru Rocky Mountain ATV...it's only $18. Dont try to jimmy rig anything....you mess up the clutch basket and that is about $80. The only other thing you could think of doing is get a copper washer and carefully wedge it in the gears of the clutch basket and primary gear...I have seen guys do that but I don't recommend it. Just get the tool...it will save you in the long run.

 

[blasterdemon7]

Get your self an impact driver . I have one with a 3/8 shaft that you can put a socket on.

 

[Xero]

Is the engine still in the bike or not? if it is just bend the washer off the nut then put it into gear and get someone to sit on the back wheel.. (Holding the brake isnt strong enough) and get a 22 socket onto a nice drive and it should come off. if its out of the bike then you will probably need the tool mentions above..

 

[Xero]

Also have you tried getting it off when an compressor and air gun?

 

[burn400]

Actually EZ...note that my advice was to get an impact wrench. I provided the alternative method if that was not an option. And a new clutch basket is actually more like 160.

 

[Blaaster]

I hope that I can explain clearly. Make sure it is out of gear.

Bend the tab on the washer so that you can get a socket with a short extension on it.

Using the longest breaker bar you have rotate it as smartly and as quichly as you can in the clockwise direction.

This will cause the whole assembly to turn.

Have something like a block of hardwood placed in the way of the breaker bar, where the end will hit, so that it comes to an abrupt halt.

The inertia of the spinning clutch, shoud keep it spinning just enough to loosen the nut.

You may needs to do this a few times, but has always worked for me in an emergency.

This method of loosening nuts is very usefull when changing grinding wheels and circular saws, where you have nothing to grab on to to hold them.

 

[EZRider76]

Actually EZ...note that my advice was to get an impact wrench. I provided the alternative method if that was not an option. And a new clutch basket is actually more like 160.

Sure, I noted. I'm just saying, ratchet strap and pry bar??? Come on MAN. Before I got my clutch removal vise grip tool, I took two pieces of soft pine and C-Clamped them on the outside of the basket. One was long enough so it would catch on the floor and wouldnt allow the basket to turn. Then, with my 3 foot breaker bar and short socket, it was nothing. The pine was soft enough for the basket to bite into it so it wouldn't spin, but it didn't scratch the crap out of it or warp it. But after I got my tool, that should've been the smart thing to do and it only took 2 days for Rocky Mtn ATV to ship it to me. By ratcheting like that, you would warp the basket or other stuff...never pull something in a direction when it is supposed to spin about 1 axis/centerline.

 

[burn400]

perhaps I didnt make myself clear...or maybe you didnt really read my post. I ratcheted the rear suspension and threw a prybar in the rear sprocket so that with the bike in gear when I turned the nut it didnt just turn the motor over. I didnt put a strap or prybar on the clutch basket...not that it really matters, I just didnt like how you come off like yea f that guy he's dumb. There is always more than one way to skin a cat, and if you dont have the right tools for the job you do have the tool that sits on your shoulders.