[flash]

Hey Guy's was in the process of taking the secondary clutch off my brothers ZX today, man that bolt is something tight!!!!! Tried everything I could think of to get it broken loose, no luck.
Is it normal threads or reverse threads ? Wanted to make sure I was trying to loosen it the right way...any thoughts on how to get it loose. Also how do you guys get yours off ?

[NMKawierider]

Hey Guy's was in the process of taking the secondary clutch off my brothers ZX today, man that bolt is something tight!!!!! Tried everything I could think of to get it broken loose, no luck.
Is it normal threads or reverse threads ? Wanted to make sure I was trying to loosen it the right way...any thoughts on how to get it loose. Also how do you guys get yours off ?

LOL...I had the very same problem. They are both normal threads meaning looking straight on at it- it goes counter-clockwise to loosen. I built super HD spanner with a 3' handle to lay across the seat frame...broke two breaker bars..exceeded 400ftlbs of torque on this bolt that is supposed to be torqued to 80 and could not get it. I finally bought an air impact that maxes out at 1000lbs torque at 150psi and a set of big-ass 3/4" drive impact sockets...then it took heating the nut with a torch then hitting it with the impact with no extensions locked in place with the spanner. It was RUST! Yes, rust. Between the nut and the clutch and on the threads...on a brand new machine that has never been in the water of mud.

Don't give up...it will come. Maybe some penetrating oil over night will help. Had I known it was that instead of bad-ass loc-tit I would have soaked it.  Good luck

[ACIDICJO]

This sounds like a cluster fuck. How the hell could something like this happen? 

[MarianT]

Sorry to hear that. with an 450 impact wrench, was enough at power 3 of 4.

[NMKawierider]

This sounds like a cluster fuck. How the hell could something like this happen? 

I do not know. No rust on the outside anywhere. It looks like salt water or something corrosive like it was trapped behind the nut. The steel of the clutch's hub and the nut were fused together with it. Once off it cleans up fine...but man...almost got the best of me. It cost me a lot of money buying stuff. I should have just loaded it up and either taken it in of down the street to my friend's shop and used his 1" drive truck air impact. That would have made short work of it. Had I known what was in there I would have flooded it with some rust-breaker like panther piss (PB Blaster), Liquid wrench or the like.

[flash]

Hey MNK, thanks for replying, I finally put it back together as we have a big ride next week, and didn't want to break anything before we go.
How do you get an impact up in there ? I had no room to do that, just used a big breaker bar along with a spanner wrench, kinda worried I would harm the clutch sheeve with the spanner. Geeesh !!!!!

[NMKawierider]

Hey MNK, thanks for replying, I finally put it back together as we have a big ride next week, and didn't want to break anything before we go.
How do you get an impact up in there ? I had no room to do that, just used a big breaker bar along with a spanner wrench, kinda worried I would harm the clutch sheeve with the spanner. Geeesh !!!!!

Take the battery cover off and go through there. I think it's a 36mm socket and the set I bought at Harbor Fraight were 3/4" drive so with the 1/2"impact I bought needed an adaptor. Just barely got it in there as there is a frame section very close even after taking the battery cover off.

I too worried about the clutch. The shelve ribs were never made to handle that much pressure. I custom cut and fitted two steel wedges to fit exactly and across from each other and welded them to a custom Y shaped handle made from 1/4"x1.25" steel flat bar. Not real pretty... but it worked. I'll post a pic tomorrow.

The thing to remember..it isn't torqued to this high torque, it's the retainer nut's shoulder that is seized and rusted to the clutch's steel hub. Try tightening it a little first to break that seize, then try and remove it. That worked for me. When you do get it to release, clean it up and coat it all with some good grease.

[flash]

Thanks NMK, yes I would like to see a pic of your tool you made, also this is on my brothers 600 EX so I don't know if it has enough room for an impact. I think the battery is under the seat in his..

[NMKawierider]

I'll get some pics. This is the impact I had to get cause my other one only put out 250lb of torque. Made the mistake of using this one on my wheel lugs..snapped them right off on low setting..lol. Even this one barely got it. It was only after hitting it forward a few spirts that it finally brought it out:

http://www.ebay.com/itm/1-2-Air-Impact-Wrench-Twin-Hammer-1-000-FT-LBS-Lifetime-Warranty-DrillHog-USA-/181631029839?hash=item2a4a0d924f:g:-hcAAOSwstxVeSCB

[NMKawierider]

Here's some pics of the stuff I had to make or buy to get the clutches off aside from the two breaker bars that I had to replace.

http://s483.photobucket.com/user/BFFreak_2008/slideshow/CFMoto%20ZForce%20800/Tooles%20for%20Clutch%20Removal

[Cosmosdan]

Getting the secondary off and adjusted has come up a few times now. If someone can do a write up next time they take it apart, that would be great. I will be doing mine this spring, and will do it if someone has not by then.

[devaldaz]

just adjusted mine and had no problems getting the nut off it came off with a battery impact wrench , but as i have found with my buggy all of the nuts are loose ! I have had to go over the complete vehicle and check the nuts!
I will adjusting the sacondary clutch again soon when my new tyres come so will do a set of photos on how too

[NMKawierider]

There's a video in the How-Tos on that.

http://cfmoto-forum.com/how-to's/cfmoto-clutching/msg1006/#msg1006