I am in the process of stripping down the zzr1200 for checking the dogs etc for jumping out of gear. The manual says remove the clutch.
The plates are all out and I was trying to remove the centre nut on the clutch hub when I slipped and have knocked one of the cast aluminium posts off the hub.
Without having the clutch hub Holder special tool is there another way that I can hold the hub to remove the nut.


Now I need a clutch hub as well as whatever worn dogs etc ....Bum

HELP

A screwdriver/spanner in between the crank/clutch gears
Not for the purists i'm sure

We made a tool to hold the clutch by welding two 30mm wide strips of 4mm thick steel in a semi-circle shape to an old clutch steel, so we could use a bar to hold it whilst we removed the nut. Hope that makes sense...........

Pictures and words.....


Clutch Steel

Prior to that, we had also snapped a post off the clutch hub. Fortunately we managed to repair the clutch hub by replacing the post with some hollow, threaded aluminium bar. First, we milled the base of the snapped post flat. We then drilled and tapped a thread and screwed some threaded bar into the hub before attaching the new aluminium post.

Phil

[Edited on 7-9-11 by Hellfire]

Many years ago I made a tool for holding the clutch - just a spare steel plate with a long handle welded to it

I use a battery powered impact wrench like this:




Dead easy

if you have any spare clutch plates then I usually drill and bolt a couple of them together to lock the clutch together, simple just drop it in, and pull it back out

impact wrench, although when doing it back up you have to guess the torque

Got it off with an impact wrench. thanks.

i like the idea of bolting together two unused plates........inspired. clever

cheers Hellfire. Had a look and i'm going to do the same thing :-)

I did Hellfires fix, but with uprated springs the post has let go. I now need replacement hub.
Anyone got or know of a zzr1200 or zzr1100 breaking? They have the same part number. If not looks like I will have to dig deep and buy new.

dont panic they are cheap 60 ish i get all mine from the usa http://www.partzilla.com/parts/search/Kawasaki/Motorcycle/2002/ZX1200-B1+Ninja+ZX-12R/CLUTCH/parts.html

as to getting the nut off all we do is to leave the plates in push firmly with your hand and use a impact gun it will fly off with ease where are you if not to far i can pop mine over

If you rivet about 3 steel and 3 clutch discs together you can just slot the whole lot into the housing and it locks it all together (assuming you are replacing the clutch discs!)

Got it off OK. just need parts now.

Starting a new thread as the fault was not what I thought it was going to be. Mystery.......