Hey everyone..
Does anyone know how to get the rest of the clutch basket off so i can remove the rest of the primary cover, then remove the gearbox and engine.
`
Undo the clutch hub nut (left hand thread)
Undo the compensator sprocket nut (right hand thread). You will need to use a strong bar for this and will have to lock the motor (for both). There are a few different methods for this, the most common being to fit a purpose made wedge in the primary chain, between the sprockets.
A simple method I use is to remove spark plug from front pot and find just before TDC, (or just after, depending on which nut you are removing) and feed in some clean nylon rope, a few feet is good. Then rotate in the direction you will be turning the nut until the piston jambs up against the rope in the cylinder. This, if done correctly, will lock the motor up firmly allowing you to swing off that strong bar to loosen the comp nut.
Once these nuts and washers are removed you can slide the primary chain and sprockets off alltogether.
Burto.
Yes, remove the tensioner as well!
If you go to Reference guides how to's There is one there from the Don called 84-99 Evo manual download.
Download it it is invaluable and beats buying the CD on ebay.
I made my own primary lock out of a piece of wood.
To remove the clutch, I found a piece of steel on the side of the road, (25 x 10 x 1000mm with holes about 35mm apart) 2 years ago. I was able to put this over 2 of the holes on the clutch basket with a socket in between the gearbox shaft and the steel. cranked the bolts up in the clutch basket and with a couple of light taps with a mallet the clutch slid off.
Oh and yes I am a certified road scab!!
Ok imagine the ruler is a nice thick bit of bar with a hole drilled where each of the bolts is sitting. Place a socket between the underside of the bar and the spindle coming out of the gearbox. tighten the bolts up (ignore that the bolts are upside down, too many bourbons and they wont stand up the correct way) This will put pressure on the socket against the "mainshaft" I think its called. if its getting really hard to tighten the bolts give a couple of light taps with a mallet. Clutch should "pop" off the shaft.
Worked for me and keep in mind I had no idea what I was doing.
Disregard what I said Kiwidave has the juice on this one, my effort is a backyarder his is the right way. Kiwidave knows his shit, helped me heaps.
I can sell you a book called "things burnzi has fucked up with stupidity and his own backyard spannering" great read!! haha
