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Thread: Clutch Boss Nut

  1. #1
    Senior Member RTG's Avatar
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    Anyone have an idea on how to get the clutch boss nut removed ( With out ) the specified clutch holder tool?



    I've tried all sorts of ways to keep it from spinning while I try to loosen the nut, but no success....



    I've seen SO many creative tricks on here, anyone have any ideas to help me out?



    Thanks!





    Clutch Assembly by Richard Todd Giordanella, on Flickr
    "I've often said there's nothing better for the inside of a man than the outside of a motorcycle"

  2. #2
    Senior Member Rainman's Avatar
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    I used an air ratchet and it spun it right off. I've done it twice and it worked great both times.
    If you can't find it, grind it

    1990 TW200

  3. #3
    Senior Member Grant's Avatar
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    I'm not sure if this would work but it's what I would try.......Put the bike in gear then tie the rear wheel rim and sprocket down tightly to the swingarm. Tie up using loads of different pressure points so as to spread the load and not risk the chance of snapping the spokes.



    Spray nut with loads of penetrating oil first and then apply pressure with a good power bar or extended ratchet.



    I have no idea if this would work but its all I can think off besides making the actual proper tool which I've normally done in the past myself ......good luck!

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  5. #4
    Senior Member RTG's Avatar
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    I have an air tool too, but the whole clutch assembly spins. I can't find a way to hold it still when I'm trying to loosen it.....



    Did you just let the clutch basket spin? I can't see how it's possible to loosen the nut if the whole thing spins...



    Does this make sense, perhaps I'm not explaining it right?
    "I've often said there's nothing better for the inside of a man than the outside of a motorcycle"

  6. #5
    Senior Member RTG's Avatar
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    Thanks Grant!



    That's a great idea!



    My bad, I totally neglected to mention the engine is out of the frame!



    So I need to figure out a way to hold it in place, even thought it's not connected to the chain etc......



    I was trying to hold it in place with vice grips but i was too afraid to stripping the out put shaft, where the sprocket mounts....
    "I've often said there's nothing better for the inside of a man than the outside of a motorcycle"

  7. #6
    Senior Member srs713's Avatar
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    Belt wrench.



    Buy one at Harbor Freight, or if you have any old straps laying around you can rig one up.
    Stephen S.

    '07 TW200:

    15/50 sprockets, O-ring chain, D2Moto foot pegs

    tweaked carb (127.5 jet, 0.019 needle shim, idle screw @2.25),

    Rubbermaid "Action Packer" on homemade brackets

  8. #7
    Senior Member TW_in_BC's Avatar
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    Is it a right or left hand thread?
    Visit my Blog...Hidden Content or my YouTube channel: Hidden Content

  9. #8
    Senior Member silverhead's Avatar
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    Are any of those metal gears behind it turning when the clutch turns? I've jammed a penny inside metal gears like that on Vespa engines when I rebuilt them to keep the clutch from turning. The penny is sacrificial given it's made of zinc, but it locks up the engine so you can remove the nut. I'm not sure it'd work in this case, and obviously don't jam it into that plastic gear
    1993 TW200

  10. #9
    Senior Member Toyanvil's Avatar
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    Install the chain on the output sprocket and hold it, put the motor in 4th gear and loosen.
    09 TW200

    04 BMW 1150GS

    61 Sunbeam Alpine

  11. #10
    Senior Member RTG's Avatar
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    Thanks guys for all the help!!!



    I finally got it, I was able to jam an old rag in the gears that stopped it up enough to loosen the nut!



    Phew, it took quite an effort to get this one though.....man was that tight, felt like a million Lb/ft to get that baby off, HaHA! Lol!



    Thanks again for the ideas!



    "I've often said there's nothing better for the inside of a man than the outside of a motorcycle"

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