EBC Clutch Removal Tool

[steve452]

Bought an EBC CT019 clutch holding tool off ebay (biker-fix) a couple of months ago. It was advertised as fitting Z1/Z1-A/Z1-B. I have checked EBC's own website and they quote the same, that it is the recommended tool for the Z1's.

Just starting on the engine rebuild and when I came to the clutch found it doesn't fit due to the fact that the basket is depressed into the casing but the tool is completely flat (see pics). Am I being a numpty here and is there a correct way to use this tool that I haven't figured out or has anyone used the same tool and found a way around it being too flat!

Would really appreciate any advice as it's stopped me dead in my tracks. I'm also going to contact EBC to ask them how they reckon it fits.

[warren3200gt]

What about putting a dog leg in it?

[z1bman]

What about putting a dog leg in it?

that's a bit cruel

[z1bman]

should have purchased one of these


https://www.ebay.co.uk/i/272392699425?c ... gKQdfD_BwE

[warren3200gt]

one of those little yappy ones, not a proper dog obviously.

[steve452]

I thought about the dog leg route, but it is pretty substantial, looks like hardened steel and is 5.3mm thick.

As for the other tool on ebay, I thought the EBC one looked more substantial at the time. Pity it didn't fit.

I'll get one from Z-Power as their's is only 19.99 and they owe me a free postage.

[steve452]

Have tried it with most of the EBC tool wedged in and the handle abutted against the edge of the auto-advance housing/crankcase join with a rag wedged in. It worked as far as preventing the clutch basket moving but would the bloody locknut move! Tried heating it up for more than 5 minutes with 2kw heat gun and used a hand impact driver but would not budge a fraction. Next route is to buy an air impact wrench and try that otherwise it''s a cutting job. Anybody got any better ideas for releasing the nut considering it's been in place for about 43 years?

[chrisNI]

Impact wrench is usually the only way of getting those off....

[steve452]

Is it possible to split the crankcase halves with the clutch basket still in place? Have tried a hand-held impact driver with a 4lb club hammer. Didn't shift it one bit. I thought if I could get the primary shaft out I could clamp it in the vice and get the nut off that way.

Also does anyone know how to get the sump pan off without breaking it? Tried heat to soften the gasket ( looks like red Hermetite as well), tried hitting it with a rubber mallet and tried cutting away some of the gasket. Nothing worked. I've checked the schematics and there don't appear to be any dowels locking it in place so not sure why it's so stubborn.

[zed1015]

Yes! cases will split without removing the hub.
The outer basket doesn't come out anyway until they are split.
Never had to resort to that myself though, a 3 foot breaker bar and steady pressure never fails to shift the nut.
The sump has no dowels.
A few sideways blows with a rubber mallet should shear the gaskets grip assuming you haven't overlooked any bolts.

[steve452]

Scrub the bit about the sump pan. Finally came off, in one piece thankfully, with a wooden drift and the aforementioned 4lb club hammer. Now gently soaking in an ultrasonic bath at 80°C.

[steve452]

Many thanks re splitting the cases. Will forge ahead with that. Thanks for the sump pan advice as well although I'd already posted the previous comment before reading your reply. Just for your amusement I've attached some pics of the progress so far, a rolling chassis. Seat still with refurbishers.

[Bill P]

Very nice indeed

[Mr Bump]

should have purchased one of these

The ones that use the same clamping mechanism as a pair of mole grips are the best - much easier to use than those ebc things (the plate is thin and hurts yr hand plus the handle is too short).

The mole grip type can be used for all sorts of other jobs too, like getting front drive sprockets off. Much more useful than those flat plates. I've never had a clutch nut that won't undo with that type of tool and a breaker bar.

Nice bike.

Olly


https://www.ebay.co.uk/i/272392699425?c ... gKQdfD_BwE