im in big clutch trouble

[sausagepartyb...]

Hi i messed up. Replaced clutch plates on my 1998 zx6r and managed to broke clutch spring bolts head off leaving screw inside (picture 1). I got new clutch assembly kit with new spring bolts but can't manage to replace them. My problem is the big bolt in the middle of casing (pic 2). When i turn it rear wheel starts turning too so I putted bar across rim spikes and swing arm to stop it turning (pic 3). I tried undoing it but it doesn't want to give in. Im afraid to broke something else and want second opinion. Should i stop being a pussy and just go for it? Is there any guide how to do it? Thanks!

[Jmh600]

You ideally need an impact driver (rattle gun) to undo the centre clutch nut....

Why do you need to replace it though?? Just get a screw extractor or reverse drillbit on the broken screws and be done with it. They won't be in there tight due to the fact there's no load on them....

Joe
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Jmhmotorcycles

[mysterious_rider]

hello. Good method, is works. Add a good 2ft of scaffold pole to your ratchet (half inch drive i hope) and crack it off.
Otherwise buy an impact gun/borrow one itll have it off easy.
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KAWASAKIIIII

[sausagepartyb...]

I already broke some stuff inside the basket so forced to replace it. I'll try to go to MOT garage nearby and see if they got impact driver tomorrow. thanks for reply guys

[cyberglass]

put it in gear get someone to hold the rear brake down get ratchet on it put a hollow bar over the ratchet handle and stand on it. thats what i do never had one beat me yet
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DL650 Vstrom 2004
DRZ400S 2003
Yamaha R1 2005

[dydey90]

[Chuffin Nora]

^^
Yeah, fuckin ratchet, FFS.
And on a clutch centre nut, F-FUCKITYFUCK!!

10mil+ bolts and 6mil+ Allen bolts require a breaker bar, IMO.*
Using a ratchet thus is just tool abuse.

When I see Delboy break 12mil brake calliper bolts with a ratchet I seriously want to break his face, the cnut.

*Inb4...
Yes, obviously a short bar, for small stuff . . .
Other [cheapshit] brands available.
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There's a fine line between integrity

[skatefreak]

Wouldn't a hammer on a ratchet provide the 'impact' to crack it?

I usually bounce a hammer off it a few times before resorting to breaker bars

[chris-red]

Why do you need to take the basket off? I did exactly the same thing (Torque wrench broke and wouldn't 'click') The snapped stud was so loose inside I just lightly hammered a terminal driver into it and turned it it came out in minutes with no agro.
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[chris-red]

[skatefreak]

Halfords advanced.
No quibble replacement ratchets
Do it all the time an not broken one personally though.

But yes, have a 90 degree widget if things get primal....

[arry]

[Polarbear]

A ratchet is for undoing things easily. To break the tightness use a decent spanner or breaker bar then use the ratchet for the x hundred turns to undo the bolt/nut.
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Triumph Trophy Launch Edition

[bikenut]

a bit of right sized wooden dowel may work, if not then steady rise up the ladder, a l/h/drill bit and reversible cordless drill should work really well though, just don't break it.

brakes on real hard in top gear, long breaker bar with hex good fit socket, long extension supported on a jack so everything is in line and wont slip, either torque ( force x radius ) or whack the end of the breaker bar with a good sized wooden mallet. you know which way to turn the nut to get it off?? what torque for fitting new nut??

90 pounds feet ish?????
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nuts about bikes

[stinkwheel]

Once you've used an impact wrench to do this job, you wouldn't bother doing anything else.

Of course what you're SUPPOSED to do is to use a couple of special tools to lock the clutch mechanism. It's apparently an easy job if you do this too.

The stuck bit of bolt would probably have come out using a strong magnet to turn it or even by tapping it round with a fine punch. Definately with an extractor.
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I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[Monkeywrenche...]

Also according to your first picture...you have the last friction plate in wrong, the last one should be in the other set of slots to the rest of the stack.

manual here
https://support.bazzaz.net/service_manuals/ZX600J8F.pdf
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2001 Aprilia RSV Mille R -dead, 2016 XSR 700-gone, 2018 Dorsoduro 900

[sausagepartyb...]

[Suntan Sid]

Assuming you don't have an impact driver, rattle gun or specialist tool, (that Stinkwheel mentioned), to remove the centre nut.

Part of the reason that you can't undo the center nut is that without the springs being bolted in place the clutch is not engaged and will always want to turn/slip.

When I reassembled mine I had the same problem.
I put the end plate back on and tightened the springs down.
Unfortunately this meant that I couldn't get the socket through the end plate, to get it on the center nut.
I removed the springs and end plate, put the sockect on the center nut and put the springs and end plate back on over the socket, the thinner neck of the socket fitted through hole in the end plate.
If you can get the socket in place like this, do what you've been doing, put the bike in gear, lock the back wheel and apply the rear break, (if you've got a willing helper).
Try and use a breaker bar, not a ratchet, as already stated.

This was done on a different engine to yours so it might not work, it depends on the clearances around the socket!
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[sausagepartyb...]

I replaced my old assembly with one i got from ebay. It seems that new one is a bit longer. Cover fits and when i put clutch disengager rod it turns very hard and I kinda need to force it. Though clutch don't move at all. And metal plates seem to be a bit thicker. Contacted seller and he told me that it's 1998 model so don't know why it should be different from mine. Are there any official clutch measurements I could compare to? My bike is 1998 reg but can she might be 1997 model?