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Discussion Starter #1
I installed (well nearly) my new clutch on the weekend..



One of the Clutch Spring Bolt/Screw broke off! Few words were spoken..



So I have a couple spares on their way.



My question is how tight do these have to be done up?

They obviously compress the spring more, giving a tighter clutch..



The harder the better for me, I just don't want to break another..



And I don't have a torque wrench..



Any help would be great!
 

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stupid question really.. do i really need to answer?


No, you don't need to answer. Tony apparently overlooked that you didn't have a torque wrench. I think we all make our fair share of mistakes. Personally, I try to be patient with others' mistakes in hopes they will be patient with mine. The book calls for 6 Nm or 4.2 ft. lb of torque on the bolts, which of course doesn't really help you out since you don't have a torque wrench. So as I see it, you have two options, either ask around and try to locate a torque wrench, or just tighten them up with a little less force than you used when you twisted them off. Free, downloadable manual here if you're interested. Clutch assembly and torque values begin on Page 135.
 

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My local autozone let me borrow a very nice torque wrench for free.



I left them with a $100 deposit, and they refunded it to me in full a few hours later when I was done with it.



Autozone is right around the corner from me, so buying a torque wrench of my own got bumped way on down my to-do list when I realized I could borrow one for free any time I want.



I think Pep boys has the same sort of deal going, others may as well.
 

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Discussion Starter #8
If you are near a Harbor Freight they have inch pound torque wrenches for $10 when on sale. If not I can send you one in tomorrow's mail.


I think the postage to New Zealand may be a bit much haha!



Thanks for the thought!



I am buying a cool little Powerbuilt 1/2"Dr Digital Torque Adapter for a good price locally
 

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I think the postage to New Zealand may be a bit much haha!


You're in New Zealand! Dang! I missed that too. I am not having a good day.



For peace of mind put a little blue Locktite on the bolt. I think you are going to be surprised how "not tight" 4.2 foot pounds are. The side cover bolts have a torque spec and should they should all be the same tightness. Good luck.



An aside: When I go to look at a used motorcycle for sale I always ask if the seller does his own maintenance. If he says yes I then ask what brand of torque wrench he uses. If he doesn't have one it tells me a lot. Point being there is a right way and a wrong way. Congrats on getting a torque wrench. Using it is well worth the effort.
 

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Discussion Starter #10
ok so the Digital Torque thing I was about to buy only goes down as low as 40nm.



the clutch springs need to be done to 4nm - is this just finger tight or what?



are there torque wrenches that go as low as 4nm, or am I wasting my time?
 

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ok so the Digital Torque thing I was about to buy only goes down as low as 40nm.



the clutch springs need to be done to 4nm - is this just finger tight or what?



are there torque wrenches that go as low as 4nm, or am I wasting my time?


It's a little more than finger tight, and yes there are torque wrenches that go that low, You just need to find the correct range of torque wrench. Here in the states 6 Nm would be equivalent to 50 inch pounds. Harbor Freight has a 1/4" drive torque wrench that ranges from 20 to 200 inch pounds. Surely there has to be something similar in all of New Zealand.
 

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ok so the Digital Torque thing I was about to buy only goes down as low as 40nm.



the clutch springs need to be done to 4nm - is this just finger tight or what?


Get a torque wrench for sure, and they do go that low. Some of the ones I've seen have both metric and standard torque measure readings.



Moral of the story:

My son tried to torque his clutch spring bolts by feel on his Kawasaki KX250F and broke one off. I was able to drill it out and use an extractor to remove the broken bolt successfully. The next day, he broke another one off. Didn't listen for some fatherly advice I guess. Now $90 dollars later, I just replaced his clutch hub! At this point, now I'm gonna put the clutch cover, springs, and bolts using a torque wrench to minimize the damage.



I don't think he'll get torqued that I'm doing the work now.
 

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Discussion Starter #14
Did you ever get the right torque wrench?


ok, so i did it. went and bought a torque wrench. tightened stuff up, then took it back and said i got the wrong thing hehe...



clutch is good.



only thing is now the kickstart is funny. not haha funny..

it will kickstart ok, but doesnt spring back into its upright position.

i knew this would happen when i was removing the cover and it half popped out.. trouble..



what is most likely in the wrong position?

i have printed out blow apart diagrams, and will attack it this weekend..
 
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