Disaster occurred yesterday while changing my clutch springs. When tightening down the new springs, I was going in a cross pattern, I was tightening down the last bolt when the three other bolt heads broke off! I was using a torque wrench which was set to 9 foot pounds so I thought I was safe, guess I was wrong...so the bolts are broken into the housing spaces for three of the four bolts. I ordered a new plate assembly, but I need to take all the plates out, how do you remove that center bolt so everything doesn't spin? My buddy and I are trying to fabricate a tool to do this...
JDLowEnd
Looks to be an M5. I would use a 1/8" to be safe but a 5/32" is the closest to the "tap drill" for a M5 thread. Be careful and center it up on the broken studs when drilling to avoid damaging the threads. Also use anti sieze on the theads when reinstalling the new bolts (OEM) and 9 ft.lbs. is a bit much for a M5 bolt in my IMHO. 54" lbs. is what I researched which equal 4.5 ft. lbs. of torque.
You should have @ least 1/2" of freeplay @ the end of your lever. With your handlebar adjuster all the way in, adjust the proper freeplay @ the engine end. This way you can adjust @ the handlebar in the future as intended.
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