Clutch Replace

[nomadmike05]

I am replacing a clutch on a 05 nomad.
My question is what is the best way to hold the clutch from turning while torqueing the clutch nut.
Any help would be appreciated.

[cactusjack]

Well, it depends on what tools you have at your disposal. The ideal way is with an air compressor and impact wrench. The stone-age way is to slip a couple of pennies (they are soft and won't damage anything) between the clutch basket and the disks to lock it in place, even then it can be a tough job to break it loose. I tried that, and was still able to turn the clutch. That's when I broke out the air tools.

[ringadingh]

Try to use an impact gun if you can, it makes it a lot easier on you and quicker. When you jam the gears with a penny it works, but you need to be strong as a gorilla to break it loose. Getting that big nut off is probably the toughest part of the job.

[gman]

Hey guys.I can't get clutch nut off,even with air tool.Any suggestions?Thanks

[nomadmike05]

I already have it together
I was just trying to torque it back to the required spec and was having problems tightening it.
Yes it was easy taking off with an impact wrench.

[macmac]

Do NOT use AIR to put that nut back ON.... Some how a vise grip chain wrench comes to mind, maybe a big strap wrench, but Do NOT USE AIR to put things on!

I use pennies, hard wood, leather and other things to jamb gears. Sometimes I try to use my chain wrench and a penny, to spread loads out.

[ndbigfish]

NomadMike,
Tighten the clutch hub nut while holding the primary gear bolt. This is the bolt on the gear to the right of the clutch basket. It helps to have a helper to torque the hub nut. I held the primary gear bolt and had the Missus torque the clutch hub nut while I watched the scale on the torque wrench.

[cyclecat]

If a good air impact, with lots of air won't take off the nut, you'll have to cut the sucker off. Brian had do to cut the first one off so make sure you order one from Mama Kaw. The nut is one of those 'specifically made for Kawasaki' things that you can't get any where else - you have to order from Kawasaki. Learned that the hard way too - didn't order one before he cut the thing and than had to wait for the local dealer to get one.

[cactusjack]

Originally Posted by gman

Hey guys.I can't get clutch nut off,even with air tool.Any suggestions?Thanks

Get a bigger wrench? Seriously, I have an Ingersoll-Rand 1/2" impact gun and a 20 gal compressor. I was using the little yellow plastic coiled hose that I keep on the compressor for inflating tires, blowing parts clean, etc. Mostly because it's a PITA to have to roll up my large 1/2" hose for everyday use. I had to bust the big air hose out to break this nut loose. Couldn't move enough air through the yellow coiled hose. Like I said, I used the penny method and a 24" 1/2" breaker bar and I couldn't break the nut loose. I'm not a little guy, either. I managed to rotate the clutch assembly, but not the nut itself.

That nut IS the toughest part of this job.

[spirello]

How many miles do you have on the bike? Chances are your clutch is fine and the spring is bad. Mine stared slipping really bad at about 38k miles I pulled it apart and the clutch looked brand new replaced the spring with a mean streak spring and it work great.

[nomadmike05]

56000 miles i placed a penny in between the gears worked fine appreciate all the help. The clutch actually looked fine so im guessing it was just the spring but replaced all any ways.

[ringadingh]

Im sure if you measure the discs and plates you will find that they are as good as new. Ive never heard of anyone having to replace them because of wear.

[cactusjack]

Originally Posted by Ringadingh

Im sure if you measure the discs and plates you will find that they are as good as new. Ive never heard of anyone having to replace them because of wear.

When I did mine a year ago, there were no signs of wear on the plates at all.