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Author Topic: KX 500 clutch removal  (Read 7000 times)

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Offline jbehunin

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KX 500 clutch removal
« on: February 10, 2011, 02:27:43 PM »
I was planning on doing a complete bottom end redo, complete with all new bearings, seals...etc..

But I have a problem.... I cannot get the clutch nut to budge. I read in my clymer manual that it is to be torqued at @75 ft pounds. I swear the person who had it before me used an impact wrench on it. I used my torque wrench as better leverage and put it on 180 ft pounds and the things clicked!!! So I know its on there freaking tight!!!

Anyone have any ideas how to get this thing to budge?
I was thinking of buying an impact wrench (i need one anyways) to try to get it to budge, but the nut looks like it is starting to round the edges... :?
I have already broke a socket trying to get it to move... :cry:

I also thought about cutting it off as well!!!
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Offline sandblaster

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Re: KX 500 clutch removal
« Reply #1 on: February 10, 2011, 02:36:33 PM »
A good impact wrench and a 6 point socket should do it.
You would be surprised how efficient a good impact wrench is.
They are so good that once in a while this can happen.

« Last Edit: February 10, 2011, 02:38:27 PM by sandblaster »
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline 1989kawasaki

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Re: KX 500 clutch removal
« Reply #2 on: February 10, 2011, 02:54:57 PM »
Quote from: jbehunin on February 10, 2011, 02:27:43 PM
I was planning on doing a complete bottom end redo, complete with all new bearings,

 the nut looks like it is starting to round the edges... :?



OH NOOO!!!
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Offline sandblaster

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Re: KX 500 clutch removal
« Reply #3 on: February 10, 2011, 02:57:40 PM »
It's not a bad thing, it's really very exciting :-o
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline kaw rider

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Re: KX 500 clutch removal
« Reply #4 on: February 10, 2011, 03:02:24 PM »
I had a K5 clutch basket nut i couldn't get off and i had to damage the inner hub to get it loose. :-D
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Offline sandblaster

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Re: KX 500 clutch removal
« Reply #5 on: February 10, 2011, 03:07:18 PM »
I bet that was exciting too  :-D
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline jbehunin

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Re: KX 500 clutch removal
« Reply #6 on: February 10, 2011, 03:10:19 PM »
I dont want to get too excited and break anything!!!
I will need a new nut, but I dont want to have to buy a new clutch hub....
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Offline sandblaster

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Re: KX 500 clutch removal
« Reply #7 on: February 10, 2011, 03:14:54 PM »
If all else fails you can take a Dremel tool to it or a die grinder.
Most of the time you don't need to cut all the way through the nut.
The heat and stress relieve usually loosens it up nicely.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Offline jbehunin

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Re: KX 500 clutch removal
« Reply #8 on: February 10, 2011, 03:18:10 PM »
Quote from: sandblaster on February 10, 2011, 03:14:54 PM
If all else fails you can take a Dremel tool to it or a die grinder.
Most of the time you don't need to cut all the way through the nut.
The heat and stress relieve usually loosens it up nicely.

i will do that as a last resort. I dont want to damage the shaft, and knowing me, I will!!!
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Offline sandblaster

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Re: KX 500 clutch removal
« Reply #9 on: February 10, 2011, 03:23:05 PM »
Just go slow and easy.
Only cut about 3/4 of the way through.
Then, take a chisel and hit the nut counterclockwise.
Sometimes that breaks it loose enough to allow you to use the socket.
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The four stroke engine: That's one stroke for producing power and three for wearing the engine out.

Motorrad

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Re: KX 500 clutch removal
« Reply #10 on: February 10, 2011, 05:13:35 PM »
I have run into them red loctited by previos owners..  Takes some heat to do away with it...  And a impact gun is ur friend on dissasembly.  Easyer on parts..
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Offline jonny500

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Re: KX 500 clutch removal
« Reply #11 on: February 10, 2011, 08:52:13 PM »
i use an impact wrench my self. but when i didn't have 1 i would put a normal socket and wrench on the nut. you need a freind to hold the socket on the nut. then use a hammer and hit the end ot the wrench and it will give the same effect as an impact wrench. it is a good idea to have the bottom end in the frame as it does a good job of holding it still. needless to say you need to be carful not to damage anything or your freind. this does work i have used it on several flywheel and clutch nuts. i am sure 10 or 20 impacts will have it off
« Last Edit: February 11, 2011, 12:27:08 AM by jonny500 »
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Offline greencannon

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Re: KX 500 clutch removal
« Reply #12 on: February 11, 2011, 12:32:44 AM »
just do yourself a favor, follow Sandblasters instructions with dremel before you do anymore damage. then go to autoparts store and buy a cheap electric impact gun with some impact sockets and work on it the proper way. It will save you time, money, and headaches. An impact is a must for certain things on your bike. I think I got mine at  Autozone for $ 60....A great alternative if you dont have an air setup.  Jonny5's method is what i used back in the day and have ended up rounded many nuts and busted many knuckles - no good and bad for your temper...lol
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Offline jbehunin

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Re: KX 500 clutch removal
« Reply #13 on: February 11, 2011, 03:07:21 AM »
Well, I tried the impact wrench, and it failed. This impact wrench is capable of 250 ft pounds.....

So, I have no choice now but to cut the d**n thing off!!!!!  :x :x :x
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Offline greencannon

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Re: KX 500 clutch removal
« Reply #14 on: February 11, 2011, 04:52:38 AM »
Sounds like some numbskull used loctite and had the incredible hulk tighten it on so it would withstand a nuclear blast....Im surprised impact wouldn't do it. was it because the nut is too rounded off already or is it really that tight ??
were you  using an impact socket ? those fit tighter have thicker walls and wont blow apart like Sandblasters picture

If all else fails, the dremel and a steady hand is the solution. use a small cutoff wheel to fit in that tight spot. have patience and dont try to bite too much at a time with dremel tool.
I always make sure there is a good working dremel tool in my garage. It is a must have...

 P.S. - dont forget a little heat if you suspect there is loctite
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