Clutch key impossible to take out - Triumph Forum: Triumph Rat Motorcycle Forums
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post #1 of 13 (permalink) Old 11-01-2012, 10:03 PM Thread Starter
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Clutch key impossible to take out

Hello,
This is a 76' T140. Man, one problem after the other ! Now, the clutch basket key will not come out. I tried WD40, ice cube, brute force with a screwdriver hitting it at a face down angle. NOTHING.
I don't own a torch, but might if you guys think it is the way to go.
Why would Triumph make it so freaking tight in the first place ?

Let me know what has worked for you.

Thanks.

Terry
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post #2 of 13 (permalink) Old 11-02-2012, 06:01 AM
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if it's loose it's more of a b*tch.

Try a basic hot air gun on it. You may be able to borrow one. It's milder and so less likely to overheat anything
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post #3 of 13 (permalink) Old 11-02-2012, 06:58 AM
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Use a punch (not a centre punch!) on the end of the key with a hammer. This will force one end down and the other end up and you then can lever it out.
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post #4 of 13 (permalink) Old 11-02-2012, 03:42 PM
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grab it with a large pair of side cutters and lever up and out
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post #5 of 13 (permalink) Old 11-02-2012, 05:45 PM
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hey
dl.allen is spot on. i did mine last night with a large set of side cutters.
Take it carefully so as not to damage the groove in the main shaft.
cheers
mal
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post #6 of 13 (permalink) Old 11-02-2012, 09:31 PM
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For keys that are too loose just get a center punch and whack a couple punch marks in each side of the key to stick it in the keyway.

Or better yet find the right size key. I have yet to get ones that fit good on brit stuff
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post #7 of 13 (permalink) Old 11-02-2012, 11:04 PM
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If it's been Loctited,it won't come out unless it's hot.
You don't want the shaft temperature to go much over 200 C.At 220 C. or more,you are doing heat treatment,and the shaft will discolour.If it only starts to go yellow,it's not a big problem.
A heat gun or 2 hair 900W driers will get it hot enough.

If that fails,you could shield the shaft with a piece of sheet metal cut out to only expose the top of the key.Heat the key until it goes blue.or even slightly red,with a torch;the shaft won't get very hot.Try whacking on the key as it cools down.

If that fails,drill a 7/64" hole in the centre of the key.You won't easily drill into the shaft,because it's hard.Tap the hole either #6 UNF X 40 tpi,or #6 UNC x 32 tpi.Use a #6 bolt with a few spacers and washers to pull the key out.

If that fails,it's bloody tight.You would then need to cut it in half legthwise with a dremel,trying to avoid cutting into the shaft.
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post #8 of 13 (permalink) Old 11-03-2012, 12:01 PM Thread Starter
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Thank you all for your replies. I was going to cut that key out but...it never came out ! I think I might know why and this is my theory : upon removing the clutch, I had seen a groove on the vertical inside case and there was NO thrust washer at all. The whole basket must have been slightly loose, carved a groove, and locked both the washer and the key from that constant loading. Makes sense ?
Why do previous owners do stupid things ?
Anyhow, I was trying to get the key out in order to pull the back cover and change the sprocket. As I was going to blow a head gasket up in my own brain with frustration from that stubborn key, I thought : " Hey, since it is lower at the base of the taper, maybe things can come out over it ? " and they all did !
I changed the sprocket, put everything back in place without ever touching that key. By the way, I had tried my friend's electric blow gun as well as a quick bite from a torch, all for nothing. I guess, I would have had to cut it out at the end.
I was so tired last night working at it, when it was time to fit the 20 new rollers in the clutch, that was pretty tough let me tell you.
Looks like Triumph made bloody sure riding one to be a special experience for hard working folks !
Terry
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post #9 of 13 (permalink) Old 11-03-2012, 05:42 PM Thread Starter
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After a clutch replacement, would you fill the 350cc for an initial fill or the regular amount in the primary case ?
Thanks.
Terry
PS: I can't believe the small size of the 3 holes between the primary case and the engine case. There are so small, I can't believe 20W50 oil can go through them at all !
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post #10 of 13 (permalink) Old 11-03-2012, 06:55 PM
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hi , i've never seen one loctited in . what I do is tap the end with a screw driver or a blunt
chisel which tips the key and then you can pull it out with pillers
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