Clutch mainshaft spacer circlip

buwgafa · Oct 12, 2010

Can someone tell me how to get the circlip off the spacer which sits behind the clutch basket. This is the one butting up against the inner promary cover. It's got me stumped ! Thanks

79x100 · Oct 12, 2010

The spacer should come off first, leaving the circlip in the groove on the mainshaft. It's then a matter of inserting a thin flat tool (OK, an old screwdriver !) along the spline and lifting the clip which is usually damaged by being removed.

Hobot · Oct 12, 2010

I use a dental pick that has a corkscrew bend in the probe, to hook under clip and get it up on top, then working pick around while trying to hold raised clip from spring back into the groove. I've tried straight and simple curved picks but corkscrew bend was the best for me.

http://www.bbsinstruments.com/scalers_s ... 2god2kFUCA
tem # ZR105R

buwgafa · Oct 12, 2010

Should the spacer just pull off over the circlip then ? I have tried with some force and it won't come.

79x100 · Oct 12, 2010

Yes, there's nothing holding it except that the circlip may have displaced slightly and expanded within the spacer. There's probably nothing for it but to keep 'worrying ' it.

Hey Hobot, do you have a workshop full of instruments of torture ?

I've just re-read your post - Has someone put the retaining spacer behind the circlip ? Is that why you said it was next to the chaincase inner ? It should be placed after the circlip and cover it before the clutch is offered up. If it is behind then you'll have to push it backwards.

pete.v · Oct 12, 2010

There is a relief in the spacer which covers the circlip to retain its position. It may be stuck over the clip. This is a stress point and the clip can gets hot and deforms. I have seen these fused together. The torque of the clutch nut is to be reduced from the manual to 40 ft.lb. and a little blue loctite.

buwgafa · Oct 12, 2010

Sounds like you're right, the circlip is easily visible in front of the spacer, so I guess its all back to front. Can I force the circlip to the back somehow ?

highdesert · Oct 12, 2010

Heinz and I eliminated the circlip and welded a large washer there so we can fully tighten as hard as we want without fear of crushing the circlip.

pete.v · Oct 12, 2010

buwgafa said:
Sounds like you're right, the circlip is easily visible in front of the spacer, so I guess its all back to front. Can I force the circlip to the back somehow ?

You better post a picture. Something sounds goofy.

buwgafa · Oct 13, 2010

Thanks all. Yes it was back to front, circlip in front of spacer. I used my wifes dental pick and managed to ease it out. Only problem now is to straighten the pick and get it back in the bathroom before she notices !

highdesert · Oct 13, 2010

No way she will not notice.

SHE knows exactly where she left it the drawer, to the millimeter.

You have no idea how much trouble you are in.

Be afraid. Be VERY afraid.

Church is out, and hell is coming your way.

74JohnPlayer · Oct 13, 2010

highdesert said:
Heinz and I eliminated the circlip and welded a large washer there so we can fully tighten as hard as we want without fear of crushing the circlip.

Did I read this wrong, or did you actually weld a washer onto the transmission mainshaft? Wouldn't that make future transmission repairs rather difficult?

Stu

Seeley920 · Oct 13, 2010

74JohnPlayer said:
highdesert said:

Heinz and I eliminated the circlip and welded a large washer there so we can fully tighten as hard as we want without fear of crushing the circlip.

Click to expand...

Did I read this wrong, or did you actually weld a washer onto the transmission mainshaft? Wouldn't that make future transmission repairs rather difficult?

Stu

I hope what he meant was that they welded a large washer to the cutch centre, so it could be tightened up like a dommie clutch!!

Hobot · Oct 13, 2010

OH yes sir your SWMBO[shewhomustbeobeyed] will Know, you used her private personal possession on something that permanently polluted it, just like all the other times you have and were told Never Touch Her Stuff. Flowers and dinner and new pick likely needed to keep some peace at home while allowing another 'woman' at home getting your devoted attention.

Welding washer in place of circlip would likely distort shaft and soften its surface temper and as well as foul removing from tranny. Definitely pay attention to highdesert advise to use only ~40ish ftlb and locktie as about 45 ftlb will deflect the circlip like a folded up backwards umbrella. Maybe the better 'upgrade' is mill wider groove for more robust circlip. If clutch nut is not definitely locked down it has famous history of coming off and going around primary drive a few times before its done ya in away from home.

highdesert · Oct 13, 2010

Yes, we welded a large washer to the clutch center, eliminated the circlip so now can tighten fully without worry of breaking circlip.

Clutch mainshaft spacer circlip

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