andat Posted December 8, 2009 Report Share Posted December 8, 2009 You know when you think it will only take five minutes....Had a bit of a problem with the clutch on my 09 250 Raga at the weekend It disengages but the lever is not coming fully back to the bars before it stops. I can hear a knock coming from the clutch case each time the lever reaches the stop, so I decided to whip the clutch out last night to have a look. My god, how hard can it be to remove a kickstart off the shaft (bearing in mind its been off two or three times in the last 6 months). I simply can't get it to shift and I'm frightened to death of prising it off what with magnesium casings and all. Any one got any ideas??? Quote Link to comment Share on other sites More sharing options...
b40rt Posted December 8, 2009 Report Share Posted December 8, 2009 Is there enough room for one of these ? http://www.machinemart.co.uk/shop/search/f...type/any/page/2 Quote Link to comment Share on other sites More sharing options...
manx2day Posted December 8, 2009 Report Share Posted December 8, 2009 (edited) I learnt a little trick from the guys at Gas Gas in the USA! GG-USA Video 7 - the clutch! Loosen the screw a couple of turns so it's protruding from the KS, swing the KS out to the start position and it should push against the screw holding it on and hopefully lever itself off the shaft. Brilliant and works every time! Edited December 8, 2009 by manx2day Quote Link to comment Share on other sites More sharing options...
andat Posted December 8, 2009 Author Report Share Posted December 8, 2009 Is there enough room for one of these ?http://www.machinemart.co.uk/shop/search/f...type/any/page/2 Just nipped down to Machine Mart and bought one of the cheapo ones. Looks as though it will do the trick. I'll let you know tomorrow! If that doesn't work I'll try Manx2days suggestion...Cheesr chaps. Quote Link to comment Share on other sites More sharing options...
jordi Posted December 8, 2009 Report Share Posted December 8, 2009 Loosen the screw a couple of turns so it's protruding from the KS, swing the KS out to the start position and it should push against the screw holding it on and hopefully lever itself off the shaft. Brilliant and works every time! Spot on.. works every time. No need for any special tool. Quote Link to comment Share on other sites More sharing options...
andat Posted December 9, 2009 Author Report Share Posted December 9, 2009 I learnt a little trick from the guys at Gas Gas in the USA! GG-USA Video 7 - the clutch!Loosen the screw a couple of turns so it's protruding from the KS, swing the KS out to the start position and it should push against the screw holding it on and hopefully lever itself off the shaft. Brilliant and works every time! Worked a treat, never even bothered with the puller. As a matter of interest, the clutch problem was immediately diagnosed: the central allen screw in the bowels of the clutch basket had worked loose and was fouling on the clutch actuating piston thingy preventing full travel at the lever end (hence the knocking). So what turned out to be a two hour job on Monday night turned into a 5 minute job on Tuesday night. Cheers. Quote Link to comment Share on other sites More sharing options...
laser1 Posted December 9, 2009 Report Share Posted December 9, 2009 You wouldnt be the 1st one to experience that problem...glad it was an easy fix. Quote Link to comment Share on other sites More sharing options...
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