Bucking bar stuck wont come out

[bad luck guy]

My 2 cents. Get a new assembly. Otherwise, disassemble the clutch side down enough to get the flower nut out of the way and you MAY be able to drive things out back through with a punch. No promises it won't damage everything and it will need replacing anyway, thus the suggestion just to get a new one. Best case scenario, you can work on it out of the engine and get it fixed. Spare parts never hurt.

The punch method worked to get it part way out, but I cannot grip it well enough with pliers to pull it the rest of the way out. I tried using vice grips too. I believe the bucking bar is the only damaged part since it came part way out. I could take the entire assembly apart to get it out, but that is a lot of trouble I would rather not go through.

 

[ImpulseRocket]

The punch method worked to get it part way out, but I cannot grip it well enough with pliers to pull it the rest of the way out. I tried using vice grips too. I believe the bucking bar is the only damaged part since it came part way out. I could take the entire assembly apart to get it out, but that is a lot of trouble I would rather not go through.

The inside of that clutch shaft is going to get damaged in the process too. Hence, I would just get a new one. As far as getting it out, a longer punch to drive it completely out is going to be your best bet. A slide hammer MAY work on the bucking bar from the other end, but you have to find a way to grab it securely.

 

[ImpulseRocket]

This is my advice as an electromechanical repair technician that has spent many years working on situations exactly like this with machine parts. Most of the time you are better off just getting a new assembly because even if you get it free, it will most likely experience odd problems or reduced ancillary part life due to slack tolerances from damage.

 

[robe]

Check out this short video that shows the internal workings of the clutch release mechanism.
There is a holding pin that keeps the internal rod from moving far. You can hammer away and all that is going to happen is the threads that engage the flower nut will be deformed.

 

[ImpulseRocket]

Check out this short video that shows the internal workings of the clutch release mechanism.
There is a holding pin that keeps the internal rod from moving far. You can hammer away and all that is going to happen is the threads that engage the flower nut will be deformed.

Yep... almost like one should remove it to make working on it easier.

 

[robe]

Yes. Remove the internal pin which will allow the center shaft to move freely. By this time you will throw it in the parts bin and install a new one.

I must add that the spring is different between them. Do check that out. some have beefier springs than others, some are taller than others.

I'd go for the heaviest spring even if it needs more preload. I'm sure someone will set me straight if this isn't entirely correct

 

[Chainlube]

Nobody told the OP that you have to split the case to get the clutch shaft out.

 

[DAMIEN1307]

Nobody told the OP that you have to split the case to get the clutch shaft out.

Chainlube...We were keeping that a deep dark secret...lol...lol...It's part of the learning process I alluded to earlier in this thread when the OP thought all he will need is just a new bucking bar and his troubles would be over.

Bucking bar stuck wont come out

True enough, I just posted that to give him some idea of price. Probably less than half that in USD. It is hard for us to post US Amazon links. They don't like for us to know that stuff is often 1/3 the cost of here. I'll give it a try just for fun.

motoredbikes.com

 

[ImpulseRocket]

I can remove a clutch shaft without splitting the cases. Just need to remove the sprocket and the key. It can be driven out the right side. You will likely need a new bearing after doing so, but I always replace the bearings when I have to remove the clutch shaft anyway.

 

[Chainlube]

I can remove a clutch shaft without splitting the cases. Just need to remove the sprocket and the key. It can be driven out the right side. You will likely need a new bearing after doing so, but I always replace the bearings when I have to remove the clutch shaft anyway.

You know, when I made that comment I was looking at the inside of the case. The step in the case is on the inside of both sides. So it could be knocked out from either side.