Beta Rev 50 Clutch removal

KTMSprocket · Post by **KTMSprocket** » Sat Jan 21, 2006 7:15 pm

I hope you can help....How do I get to the clutch springs? They are behind some caps....cheers?

Rob W · Post by **Rob W** » Sun Jan 22, 2006 8:18 am

I've not taken the 50's apart, but if you look at the exploded engine diagram you got recently, you'll see a spring clip (Seeger, part 64). It holds the clutch spring holder plate (part 67) which locates the caps you see. The springs are located by, and under, the caps. Pop the spring clip out see what happens. It will oviously be under some pressure, but I don't know how much, so take care. Let me know how it goes.

KTMSprocket · Post by **KTMSprocket** » Sun Jan 22, 2006 5:35 pm

Rob...Yes. I'm happy with the diagram etc....but that retaining spring is under a lot of pressure. If I was able to pop it off, it would not go back without a tool or some specific knowledge of how to do it. Thats why I stopped.

((Its not easy to pop that ring off because it actually sits in a recess, so the clutch needs to be compressed I think before it can become free enough to remove))

Rob W · Post by **Rob W** » Mon Jan 23, 2006 7:01 am

Big Hammer :shock:

Have you asked this question on trials central? Tends to be a few more guys with experience of the little betas over there?

KTMSprocket · Post by **KTMSprocket** » Mon Jan 23, 2006 8:18 am

rob...yes, I have a post on it and may have a lead to getting it fixed. it looks like you need a puller but I am not sure if its a dedicated puller or a more generic one. time will tell....and we all have lotsa time don't we.... 8-)

KTMSprocket · Post by **KTMSprocket** » Tue Jan 24, 2006 9:06 pm

I ended up making a compressor...it took about two hours of measuring, cutting, bending, drilling, tapping and screwing. It took about 1 minute to get the clutch apart!!!

Rob W · Post by **Rob W** » Wed Jan 25, 2006 9:55 am

Ah I love home made tools - ask the beta mini bike guys up here about my universal fork seal remover/installer. Rrruff :shock:

Looks like the hooks fit under the clutch basket. How did you release pressure from the seeger - threaded bolts (can't see a hole - was it the same ones that hold the jigger together) or jemmy bar? Would only need pressure for a second or so, right? How far does it need to move down (1-2mm my guess) and how far up do the plates etc come up once the pressure is removed?

Questions questions - Just storing information for when I have to make one. Thanks

KTMSprocket · Post by **KTMSprocket** » Wed Jan 25, 2006 12:46 pm

Rob, Ok...will try to give u an explanation...

The objective was to be able to remove the retaining ring, cover, springs retaining cups and springs so that I could remove X number of springs to make the clutch easier to operate for my 6 yr old (I must emphasis this is an experiment and I may have to reverse my actions).

Once the clutch cover was off I was hoping to prise off the retaining clip that held down the cover (see the upside down view in the photos above). Unfortunately the design is such that the clip is pinched into a recess by the action of the clutch springs on pushing on the plate (via the spring cup shaped covers). So...you need to compress the springs via the plate such that the retaining ring is not under pressure. Then a small screwdriver can be used to flick the ring out.

I made a legged tool to hook behind the ring gear (not the basket) that would then straddle the clutch assembly with a bit of clearance. The intent was to then tap a hole or two in the tool such that i could screw down a couple of 6mm cap head screws to compress the plate and springs. The idea was ok so I made a one piece tool initially, but found that there was not enough room in there to use it. I then added a brace plate and cut the legs the metal that spanned the legs, into two. This allowed me to assemble the tool in situ and get round the narrow space issues (6mm stainless screws were used - long for compression, short for assembly).

The plate needs to be compressed about 5mm to give you enough room to prise out the retaining clip. This was very easy by the way.

Then, slowly I unscrewed the longer screws to slowly release the spring tension. eventually the whole assembly went loose and I disassembled the tool and this allowed the plate, spring cups and springs to fall loose.

NOTE: The dome shape disc remains in place and covers the clutch plates. This is great because it means you can have a staged dismantle of the clutch instead of the whole lot falling out at once!!!

After I have re-assembled with less springs I'll report on whether it worked or not ...... 8-(

Hope this helps....