2nd gear time, Help

[DavesXS]

I havn't even got past the clutch yet

That clutch bolt(the one supposed to be torqued 51 lbs). Well I have 3 ft worth of breaker bar, and throwing my back into it, I am applying 150+ lbs and not budging. I even soaked in PB while I went to get a socket.

What do I risk breaking if I continue to apply more pressure. I can get 5 ft cheeter bar and really crank it but is this nessasary? I don't want to snap anything vital(or not vital)

What if I heat it with a torch?

Man this sux

[DavesXS]

Ok, After 75$ impact wrench half can of PB, and 20 min of letting the impact gun bang on it it finally came lose.

By the way, 1 1/8 is the socket. It failed to mention that in the DIY.

On to the next thing...

[powerram50]

at least you got it off without breaking it.

[DavesXS]

Now the gear assy wont come out. 5th is out and the assy slides back and forth, but the gears below won't allow it to come far enough to clear the hole on the other side so I can lift it out. Looking at just replacing 5th. The dogs show 99% of the wear. The slots are not rounded off. I'll wrestle with it a couple more hours, but its looking like rain, and I screwed if it does.

I'm gonna have half a dozen clips and bolts left over when this is done.

[DavesXS]

Rain coming in about an hour and a half.

No help?

Some kind of trick to getting this thing out?

[trbig]

I have always just pulled the motor and split the cases to do this, so I am not much help in that department. BUT.. I will say that if you only do the dogs and not the slots... you'll be wasting your time.

Tod

[DavesXS]

ok This is what I had to do. I ground down new gear dogs, and the old gear slots. Slipped them together and checked the match up on them. While I was at it I replaced clutch springs with 10% heaver new springs. And new clutch pads.

Its all back together now sept the bottom pan. Since grinding slots inside the motor, I will pour oil into it and then flip it on its side. Let it drain, spray oil up into it and flush good before putting pan back on.

Now it rains

[trbig]

there's still going to be a lot of metal shavings in your motor. If you can find a magnetic plug, use that.. or at least a small magnet in the pan to hold onto that stuff until the next time the pan comes off. A simple oil drain won't get rid of all that.


Tod

[DavesXS]

Good sugestion. I have some small powerful magnets real slim, will work perfect. I have no problem pulling the pan a couple more times in the next 30 days.


I noticed the gears don't mesh 100%. In my hands the dogs go all the way to the edge of the slots. But installed the dogs only engage half way through the slots. I checked how they fit minus a C clip between the 2nd and 5th gears. They meshed all the way. But I don't dare run w/o the C clip installed. And it wasn't untill I got it back together and flipped I realized I can grind the pocket the C clip fits into on the 5th gear, allowing the gear to fit snug to the other. If I ever have to do this again thats going to be part of it. I could see the angle grinds I made pull the gears together when I saw them barley grab.(running through gears while up side down)
Clutch feels more firm with the new springs. Kinda like my old kz1k did.

Fresh fire red pearl paint on panels, tank, and fenders, every thing else is here sept handle bars.