Lightning
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| posted on 7/9/11 at 08:45 PM |
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Dropped a bo77ock in stripping ZZr1200
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
Steve
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ReMan
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| posted on 7/9/11 at 09:02 PM |
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A screwdriver/spanner in between the crank/clutch gears
Not for the purists i'm sure
www.plusnine.co.uk
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Hellfire
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| posted on 7/9/11 at 09:11 PM |
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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]
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clairetoo
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| posted on 7/9/11 at 09:34 PM |
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Many years ago I made a tool for holding the clutch - just a spare steel plate with a long handle welded to it 
Its cuz I is blond , innit
Claire xx
Will weld for food......
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mookaloid
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| posted on 7/9/11 at 09:41 PM |
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I use a battery powered impact wrench like this:
Dead easy 
"That thing you're thinking - it wont be that."
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tony-devon
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| posted on 8/9/11 at 06:30 AM |
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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
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matt_gsxr
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| posted on 8/9/11 at 08:53 AM |
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impact wrench, although when doing it back up you have to guess the torque 
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Lightning
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| posted on 8/9/11 at 07:42 PM |
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Got it off with an impact wrench. thanks.
i like the idea of bolting together two unused plates........inspired. clever
Steve
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Lightning
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| posted on 13/9/11 at 07:19 PM |
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cheers Hellfire. Had a look and i'm going to do the same thing :-)
Steve
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Lightning
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| posted on 21/5/13 at 05:58 PM |
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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.
Steve
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rick1962uk
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| posted on 21/5/13 at 06:04 PM |
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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
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luke2152
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| posted on 21/5/13 at 07:01 PM |
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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!)
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Lightning
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| posted on 21/5/13 at 07:12 PM |
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Got it off OK. just need parts now.
Steve
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Lightning
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| posted on 21/5/13 at 08:55 PM |
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Starting a new thread as the fault was not what I thought it was going to be. Mystery.......
Steve
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