Zagg's Project: '78 GS750E

[Zagg]

As far as the clutch cover, I did finally get it off. Only one of the bolts came out without stripping. I've been working on them for several weeks now on and off. Broke all of my flat head bits. I bought a Dewalt flat bit and that worked out great. I got the last 5 last night. My method has been to hose them down with PB Blaster, work them till they stripped with a JIC head, then grind a straight cut with the dremel for a flat bit on my hammer drill. I was having trouble controlling the torque on the air impact and was chewing the hell out of the bolt heads so I switched to my hammer drill until it started smoking. Anyway, these were the last two. No way to get at them with the dremel...



So to solve the problem, I used a 1/8" drill bit, made a punch mark, and drilled into the head. I did the same thing on the other side. Worked well.


Adding heat seemed to be the key as well as switching back to the impact driver.






Clutch plates are out. I will be inspecting everything per the manual. Because the bike has 30k on it I already ordered new springs and plates. Updates this weekend.

[Zagg]

Pulled apart the clutch assembly tonight... Didn't find anything out of the ordinary, but check out the cracks in this first pic! I didn't see them with my naked eye at all. I think it is flaking, but I will inspect it much closer tomorrow. Everything is still open because I snapped one of the retainer spring bolts...



I'm posting these because I don't know what "abnormal" wear would like like on this housing cover. The Clymer doesn't say much about what would fail the housings or sprockets but common sense is telling me these are okay.... or maybe it's my bank account. Not sure. Either way, I'm rolling with it.


Not sure what would have caused this. Looks like a bolt was spinning on it with some real pressure, but I am fairly certain that the clutch case was a virgin when I cracked it open and I did not see any metal shavings and just a few scuffs and scrapes inside the case.




Springs good, gear teeth good...

[Zagg]

Bearings were all in good condition.


A little bit of surface rust from being bone dry for who knows how long, but the teeth are good...



I played with the dog I believe it's called and it clicks up an down very well. My shifting issue is somewhere else. I am hoping it is from the clutch plates on the low end of tolerance along with the lack of lubrication but we will see once it is back together.

Crankshaft teeth look perfect.


These teeth are a lot nicer than mine and all I've been chewing on the last 39 years is meat, veggies, and the occasional piece of fruit.


Mmmmm... Clutch plates....


Sprangs!

[Zagg]

I snapped one of these upon re-assembly.


I drilled a hole into it with a 1/8" bit and tapped a JIC head into it. I was able to screw it out that way. I didn't do it, but I believe the hole is threaded the whole way through. If you ever snapped one you could screw it out the other side instead of reversing it out like I did. The bitch of it is that I was using a torque wrench to put them back on. I was at 4.5lbs setting when it snapped and hadn't quite gotten there. Spec was 3-6? 3- 9? I don't have the book here but either way my torque wrench is way overkill for anything under 20lbs. I bought it to torque head bolts on a 7.3idi cylinder head to 110lbs. My fault.

[halz426]

I did the same thing when I replaced my clutches/plates & springs using a small 1/4" harbor freight torque wrench, ( returned it and didn't trust the second one) returned that one as well.. Drilled it and used a reverse drill bit (easy out). Glad it worked. Never again will I trust one of them (at least a cheap one), I just used my trusty "manual" torque gauge to finish it (feel). : ) Glad you got it worked out.. Looking forward to seeing your progress.

[Zagg]

I did the same thing when I replaced my clutches/plates & springs using a small 1/4" harbor freight torque wrench, ( returned it and didn't trust the second one) returned that one as well.. Drilled it and used a reverse drill bit (easy out). Glad it worked. Never again will I trust one of them (at least a cheap one), I just used my trusty "manual" torque gauge to finish it (feel). : ) Glad you got it worked out.. Looking forward to seeing your progress.

Thanks Halz. I was a bit nervous, but just went after it and was able to work it out. I have a Husky torque wrench which I researched for hours so I know it is a good one, but like I mentioned it is not for "light duty" work.

[Zagg]

Got everything back together (almost) I couldn't source the two long bolts for the cover locally so I will order online. I replaced all 6 of the bolts and washers for piece of mind. After checking the "cracks" in the housing I found they are more of a silvery deposit. Dunno, just relaying the info. Either way, everything is good to go and as soon as I get the couple bolts I need I will button er up and fill er with oil.