TOPIC:

Did you use an impact driver w/#3 bit to try to remove the screws?

Unrelated to the clutch adjustment. Someone got rid of the oil gauge sight glass. I would look into installing a new one. I believe Z1Enterprises has them. Or if need be, replace the clutch cover with one having the sight glass.




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Looks like someone rattlecaned over the sight glass. It should be possible to clean the lens.

Yes it's painted over. I'll clean it or get a new one once the cover is off.

Paint. doh . I just glanced at the pic.




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Many thanks to Nessism. The impact driver worked like a charm. The cover is off. I removed the lifter plate pusher and the ball bearing was in there. I then noticed that the clutch hub nut was loose. Like finger tight loose and it had backed off. I could turn it with my fingers. When the PO replaced the clutch he apperantly didn't torque it to spec and it worked itself loose. I assume that when I was pulling in the clutch lever the whole clutch assembly had moved out and that's why I ran out of adjustment. All the plates appear fine. I just need to tighten the nut down. Is this possible without the special tool? I've seen online some references to using a strap wrench. Has anyone done this? Thanks again for all the help everyone.

You can get a EBC holder tool off Ebay for 18 bucks or so.... a strap might work but you really gotta crank on it... 100 lbs or just under...... you really should replace the nut too since it had a locking tab built into it (the manual recommends it along with the thrust washer which I did too (maybe could by without it though??) ... I used blue loctite too just to be safe. Good job on finding the problem before it got dangerous for ya.

Just bought the ebc holder and nut on EBay. Thanks KZB2!

Good catch on finding the cause of your issue! That would have made a mess if that nut came off when you were riding.

Final Update: After much delay due to work, family, wrong parts, and a much needed short vacation everything is back together, torqued properly, and working great. Thanks to everyone for their help and knowledge getting this fixed. Very much appreciated.

Are you able to provide the source for you lock nut? I can't seem to find one anywhere.
Thank you