Clutch arm removal troubles

[Chri5]

Hi,

after owning my K for nine months picking at it a bit i decided to take a look at why my clutch is stiffer than a Harleys my first thought was adjustment but its all correct so i ordered new roller bearings for the clutch arm but the thing is not moving ive removed the cable, the 2 circlips and the washer but the pin will not move.

i dont want to go all angry gorilla on it as ill most likely smash the mounts on the gear box. ive tried a little heat and freeze spray and Plus-Gas (my go to penetrant) is there any tips or tricks out there for when this gets stuck without cutting the arm in half and buying new

[The Mighty Gryphon]

One of the things you want to do is to install a grease fitting so that you can grease the clutch arm from time to time.   With that in mind, I would get a fitting and a drill bit for it. 

Drill the arm in the middle being careful to feel for the break through from the aluminum arm to the steel shaft it rides on.  Then you can use the hole to inject penetrant into the arm.  By applying the penetrant from the ends and the middle and a lot of movement on the arm, you should be able to free things up enough to get the shaft out.

Once you have everything apart, you can clean up any dings the bit did to the shaft and install the grease fitting. 

One thing, when you drill the hole, make sure the arm is in the normal position it would be in when the cable is attached and properly adjusted.  This will make sure that it will be easy to get your grease gun on the fitting.

[Chri5]

ive seen the posts with the nipples installed and i was going to do that after removal, i will try drilling it insitu as it just wont budge and hopefully i can get it out it the poor girl was neglected in a past life i had to drill the swing arm pins too

[wally.fisher]

Pins are hardened best to use a Dremel cut it out, not easy though.

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[The Mighty Gryphon]

Actually, the pin being hardened is a good thing.  Makes it harder for the drill bit to ding it up.  I've drilled three clutch arms for grease fittings with no ill effects.  My advice is not hypothetical, it's from experience.