What else can go wrong? Clutch Removal - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 24 (permalink) Old 04-16-2007, 12:39 AM Thread Starter
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What else can go wrong? Clutch Removal

In my quest to replace the head gasket (lower one), I have to remove the clutch rotor and basket. Since I don't have a spanner wrench as called out in the Clymer, I put serveral of the friction plates in the clutch and reached thru the basket and clamped them with a pair of vice grips. This held the clutch pretty steady.

However, while I was holding the clutch, my buddy was trying to loosen the clutch nut using a 30" breaker bar. It wouldn't budge! Upon closer inspection, the clutch nut was staked to the shaft!! Why in the heck would anyone do that??? This shouldn't be this hard!!

Does anybody have an idea as to how to get this off??

We put enough force on it to try to remove the nut that we broke one of the ears off a clutch plate (no big deal - I was replacing them anyway) and cracked the basket (that is a big deal). Very, very frustrating.

I will put the engine in a box and take it to the dealer tomorrow and see if they can get the damn thing off (and to order another clutch basket).

Perhaps I should have just replaced the ACCTs to quite the chain and left everything else well enough alone. Oh well. I just hope it isn't good money after bad.

Jeff
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post #2 of 24 (permalink) Old 04-16-2007, 04:08 AM
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I'm not positive, so someone correct me if I'm wrong, but I think the nut has lefthanded threads.




Count down = 10


AKA: Tim & 'The Adventure Cycle' VROC #24567, NEVROC, SteelCity VROC


"When life throws you curves,
Aim for the apex."

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post #3 of 24 (permalink) Old 04-16-2007, 06:26 AM Thread Starter
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Quote:
Originally Posted by hyperbuzzin View Post
I'm not positive, so someone correct me if I'm wrong, but I think the nut has lefthanded threads.




Count down = 10
There certainly isn't anything in the Clymers about left handed threads.

Anybody have a good used clutch basket they would like to sell?

Jeff
 
post #4 of 24 (permalink) Old 04-16-2007, 01:57 PM
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I think I was wrong there.
I just checked the Kawi manual, and it says.....

"Hold the clutch hub from turning.
Turn the wrench counterclockwise"

So, it isn't lefthanded according to that then.

Sorry 'bout that.

Countdown = 9


AKA: Tim & 'The Adventure Cycle' VROC #24567, NEVROC, SteelCity VROC


"When life throws you curves,
Aim for the apex."

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post #5 of 24 (permalink) Old 04-16-2007, 02:09 PM
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I may have a clutch basket. Let me check the parts department tonight. I thought the clutch basket took a special tool for removal..

Dianna
Conway, AR
Patriot Guard Rider
2000 VN750 Sere (Serendipity)
1990 GL1500 (Ole Blue)
1986 VN750 EVie (project bike, heavy custom)
VROC # 11628 / 25000-H
ARVROC # 12 Coordinator and Crowd Control
OKVROC # 18 (H)
TNVROC # 45 (H)
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post #6 of 24 (permalink) Old 04-16-2007, 02:13 PM
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Yeap I was right.. Here's the post
FYI. Scott from the main VROC board wanted me to forward this to
all of you in case anyone was interested.

If someone could post it over at www.vn750.com, that would be great
too.

You can contact him at [email protected] as he
is not a member here or over at VN750.com.


*** START ***

Good afternoon y'all,

While re-assembling a VN-750 motor in my garage, I ran into a bit of
a
stumbling block... getting the clutch hub nut and the nut on the
output
shaft torqued to spec. Looked like it needed some kind of special
tool, so I
made one:

http://makeashorterlink.com/?I2EC35AFD

I'm not sure when I'll need it again, so if any of ya are rebuilding
a
VN-700 or VN-750, and want to borrow my cool clutch hub tool, drop
me a note
and I'll send it (as long as I get it back!!!).

Could somebody copy this over to the 750 Forum too, please?

Counting down to the Mini-Rally!!!
--
Ride safe!
HotSauce & Margot
~V~ 2064/1561, AMA, IBA
~V~14000H
Scurrilous
Palm Bay, FL
"Your first failure is not to try..."
Thanks Rick...

Dianna
Conway, AR
Patriot Guard Rider
2000 VN750 Sere (Serendipity)
1990 GL1500 (Ole Blue)
1986 VN750 EVie (project bike, heavy custom)
VROC # 11628 / 25000-H
ARVROC # 12 Coordinator and Crowd Control
OKVROC # 18 (H)
TNVROC # 45 (H)
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post #7 of 24 (permalink) Old 04-16-2007, 02:24 PM
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It takes a special tool to hold the clutch basket from turning. If the nut was staked, it is a simple matter to take a punch and unstake the nut. It is staked so it doesn't come undone while riding which could be disasterous.
The nut is a normal lefty loosey, righty tighty nut. It just takes the special tool or facsimilie thereof to hold the basket while turning it. You can make the tool yourself by obtaining a Vice Grip type welding clamp and drilling and tapping two appropriatly spaced holes for some bolts. These bolts go in the grooves of the clutch basket to hold it.
I got mine off by using an air impact wrench while holding the clutch basket with the tool.
The only left hand thread bolt is the one that holds the left side balancer ( I think, or is it the right side?) assembly as the balance drive rod is threaded all the way through.
If you look at the torque specs for the clutch basket nut, it is quite a bit. I don't have the manual at work so I can't give exact figures but if memory serves, it was about 80lbft or so.
Once you get it all back together, you will be rewarded with a great running bike and the ability and confidence to tackle any repair issues that might crop up.
If you absolutely need the proper special tool, Ron Ayres has one under the Motion Pro brand for about $30 or so. It's the same tool Kaw wants $70 for.

Jim W
93 VN 750 "Ursula"
Moved R/R 08Sep06
R/R rewire 17Feb07
New R/R, Installed 14Jun08
New Stator installed 10 Jun08
Maintenance Free Battery 12Jan08
21480 Miles
VROC #8542
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post #8 of 24 (permalink) Old 04-16-2007, 03:01 PM Thread Starter
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Thanks for the feedback. However, I am taking the motor to my local dealer to get the nut taken off.

I may have called the part I broke by the wrong name. The broken part is shown on the Ron Ayers site as "Housing-Comp-clutch" p/n 13095-1302. It is the outer aluminum ring with the gear on the back. Expensive!

Jeff
post #9 of 24 (permalink) Old 04-16-2007, 03:09 PM
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OUCH!!! What did you break?? That part should be almost bullet proof. It's the clutch basket that's made of the worlds softest aluminum.

Jim W
93 VN 750 "Ursula"
Moved R/R 08Sep06
R/R rewire 17Feb07
New R/R, Installed 14Jun08
New Stator installed 10 Jun08
Maintenance Free Battery 12Jan08
21480 Miles
VROC #8542
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post #10 of 24 (permalink) Old 04-16-2007, 06:08 PM Thread Starter
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I cracked one of the landings where the clutch plate tabs go. I had the bright idea of putting several clutch plates and friction plates in the housing and reaching thru the openings of the housing to clamp them together and lock the basket in place. It worked great too. We were able to really torque on the clutch retaining nut without anything slipping.

However, due to the nut beign staked, we couldn't get it to budge. While getting a better grip, I must have jambed one of my vicegrips sideways and heard a pop. It cracked off one of the clutch friction plate tabs and cracked the landing in the housing. I didn't care about the friction plate since I am replacing them anyway. The clutch housing is another matter.

I believe, if the nut had not been staked, it was a brilliant plan. However, that was not the case. We will see how the dealer can do tonight.

Jeff
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