Undoing the Clutch Nut

[Ingah]

NB: I haven't done this task before.

"Unstake the nut using a small punch" (Haynes).
Cue punch pushing against the groove and no appreciable movement, nor any prospect that if i push harder i'll do anything but break my punch or slip (?), so i simply assume it's unstaked and continue.

"a) If the engine is in the frame, engage 1st gear and have an assistant hold the rear brake on hard with the rear tyre in firm contact with the ground...

Unscrew the clutch nut".

27mm socket, 3/8" to 1/2" drive converter, 3/8 drive socket tool, girlfriend pushing the brake down hard, and ultimately, no movement at all from the clutch nut.

Nor is the "service tool.. Pt no. 07GMB-KT80100" available any more.

My garage does not have power, nor do i own a compressor, so i assume that obtaining "air impact wrench" is out of the question too.

Is there any other method?
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-- Ingah

[T1z3R]

you press the brake and get your gf to undo it?

they are buggers. a good fitting 1/2" socket and a decent length breaker bar or similar and plenty of grunt should do it.
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duck my sick!

[.....]

You can get battery electric impact wrenches as well and I've used one in the past to undo a clutch nut. In fact I think it might be more powerful than my air one. Maybe see if you can borrow one? If you're planning on doing regular maintenance it could be worth investing in one as they do come in very handy.

[.....]

By the sounds of it though, you haven't unstaked the nut properly, I'd concentrate on that first.

[Ingah]

[Ingah]

[.....]

I've got one like this

https://www.twwholesale.co.uk/product.php/site/froogle/sn/ROL70789

They're not cheap but when you've got something stuck and this effortlessly removes it then you realise it's money well spent. Great for front sprocket nuts as well.

Having said that, I'd give it a go making sure the nut is properly unstaked first and get a breaker bar or similar on it.

[Ingah]

Would this do the job as far as impact wrenches go, or is it missing something?
https://www.tool-net.co.uk/p-345442/lamborghini-19-2v-impact-wrench-bare-unit.html

(yes i'm aware it's unlikely to last me, but in the present situation the choice is to rent, seems to be anything up to £60 for a week - i.e. no chance, get someone to come out to do this hopefully 5 minute job for me for hopefully less than £30 but could well be more, or buy this or something similar and at least i'll at least have something to use next time!)
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-- Ingah

[mj04uk]

Just had the same issue on the WR, last time Joe kindly loaned me his battery one, but I got a draper hand held jobbie (£10 from Amazon) a while back.

Two solid strikes and job done.

[Ingah]

[Ingah]

[loply]

When it says to unstake the nut, is it not referring to a locking tab washer arrangement?

If not, I concur about using an impacter of some kind, ideally pneumatic...
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Yamaha SZR660 Caution to the wind, the throttle pinned!

[Phoenix]

[Ariel Badger]

[Ingah]

@loply, i don't know. It's a CB500 if it helps, but i don't understand what that you said means. However, i deduce that this could be relevant: "The clutch nut is staked against a groove in the transmission input shaft". Hopefully this clarifies things?

@ Phoenix, the thingy i'm using is not very long, certainly less than 10". It's from Halfords middle-of-the-range Professional socket set.
And understood about the difference between impact wrench and impact driver now

So i guess the next step should be to buy either?
A) https://www.machinemart.co.uk/shop/product/details/pro77-1-2in-drive-breaker-bar
or
B) https://www.machinemart.co.uk/shop/product/details/clarke-pro210-half-inch-drive-breaker-bar

Although, hold up, isn't this the same thing, but i get 5 different lengths to choose from (the largest one is 50cm / 20inches)?
C) https://www.machinemart.co.uk/shop/product/details/pro-55-5-pce-1-2in-drive-ext-wobble-b

However, is there any possibility this could fail to work, or i won't be able to properly unstake the nut? (because if so i'll get an battery impact wrench instead as i need it to work!)
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-- Ingah

[Ste]

[Ingah]

Right-o, option B) is going to be ordered. I'm also going to order one of these clutch holders as it seems i will need one from all the googling i'm doing (guess i just gotta cross my fingers and hope these 2 things will do the job between them)
https://www.motionpro.com/motorcycle/partno/08-0008#

I'll take and post pictures tomorrow for further clarification (as it's now too dark) - if it clarifies at all i have successfully slackened and removed the clutch release plate bolts, the plate itself, and the springs, leaving the clutch nut exposed. I suspect i may have failed to unstake the clutch nut as nothing moved when i was pushing on the groove.

Edit: Whilst this isn't the manual i've been using, i suspect page 2 of this document will help clarify what i'm doing precisely:
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-- Ingah

[finpos]

On page 9.2, there is a little box showing the nut with a circle in it. That's showing you where the nut has been staked - Part of the nut's soft rim has been bashed into a slot in the shaft to stop it turning. You need to get a punch and bash it into the slot so the punched in bit of nut gets the hell out of the slot, it should then be free to turn. You should be able to drive the punch right in so you can see a gap between the nut and the shaft. Note you're not moving anything, you are bending the rim of the nut back. If you can't clearly see that it's not happened.

Using the tools you have (i.e the worst option, no impact gun and no clutch holder) you should be able to overcome the brake and spin the back wheel if you are putting enough shove into it, once that starts happening you are nearly there - more weight over the back wheel or jam it with broom handle. If you're not turning the back wheel, you're not pushing hard enough!

f.

[Raffles]

The clutch centre locknut incorporates a soft metal ring on its outermost face which is purposely distorted into one of the splines on the transmission shaft once it has been fully tightened. ''Unstaking'' is simply a matter of remedying this distortion with a centre punch or suitable small chisel. Once you have unstaked the nut take your bike down to your local friendly tyre fitters and ask them nicely if they will remove the nut for you. It will take only seconds and should not cost you a cracker.
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A good loser will always be a loser.

[Ingah]

Thanks, that's really helpful stuff there.

I've ordered the clutch holder and reserved the 24" breaker bar, so i'm hoping that further events will proceed as follows:
1. I will unstake that nut using a hammer, a punch, and brute force.
2. The clutch holder holds the clutch basket as shown in that manual i linked, whilst the 24" breaker bar and my brute force will make it turn.
3. The above is successful and the insides of the clutch aren't too fubar-ed.
If this somehow fails, i will be forced to push the bike over to my local friendly mechanic and throw myself upon his mercy to undo my nut (as i've now spent the money i could've put towards an impact wrench thing).

Cheers all, will update as and when, although i'm more optimistic it'll be positive now i'm using more suitable toolage.
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-- Ingah

[yen_powell]