sparks key install help

[timo_d135]

hey guys im in the process of installing my sparks key and i cant get the case to brake loose. any ideas.

p.s. im following tri5rons write up on the install

[honda400ex2003]

make sure everything is loose then lightly tap with a rubber mallet. it is held on by the gasket right now. :D be careful it will take quite a hit to crack it but its been known to happen.

steve

[timo_d135]

iv been using a rubber mallet, im just scared ill crack it

[honda400ex2003]

check around it for slots to put a flat head screw driver in also, im not sure if the flywheel side has them but its worth a shot.

with a rubber one you shouldnt have to worry about cracking it unless you really hit it hard.

steve

[Ryan'07400ex]

Had the same problem helping a friend. just be patient. try getting a long screw driver and hitting it from the opposite side on those little tabs sticking out.

[timo_d135]

i finaly got it, just had to get angry at it. thanks

I use a crowbar and pry (GENTLY) where the clutch arm comes out (pry on the case not the arm)in the most solid looking area there.If you're one of those guys that strips and breaks 90% of the bolts in ur path this may not be the approach for you.You may need a small block of wood as a backing plate.Take ur time cuz you only do it wrong once.I've used this method 6-8 times.good luck

[sheweezy]

You have a clutch arm on the flywheel side??

[honda400ex2003]

Originally posted by PAxcThumper
I use a crowbar and pry (GENTLY) where the clutch arm comes out (pry on the case not the arm)in the most solid looking area there.If you're one of those guys that strips and breaks 90% of the bolts in ur path this may not be the approach for you.You may need a small block of wood as a backing plate.Take ur time cuz you only do it wrong once.I've used this method 6-8 times.good luck

wrong side man...

steve

[timo_d135]

i got the key in and the cover on. then i went to tighten the bolts and i broke one off (the starter cover upper right bolt)

what should i do. can i just put other bolts and call her good. or drill it out

[honda400ex2003]

if you can get it out the other side of the case that would be the best way. if you can get a notch in it with it hanging out, you might be able back it out if possible.

that doesnt sound like the case though, it sounds like it was broken down in there. options~ drill it with a small one and keep getting bigger to get just the threads then try to back it out with an easy out or you can pull the threads out depending on how far in it is.

that would be my options first.

steve

[sheweezy]

x2, you can get an easy out set with a few diff size bits and easy outs for under ten bucks at walmart, lowe's, etc. It will come in handy later down the road too...start with the smallest size and work your way up with the easy outs until it comes out...

[timo_d135]

good news!!!! i got the bolt out, was sticking out just enough to get with the needle nose.

now how should i replace the bolt. should i take one for the team and order a oem one. or do you think ill b able to get something from the hardware store.

thanks for all your help

[sheweezy]

good deal man...

As for a new bolt, that is just kind of your discretion...it is a 6mm bolt and the right side starter cover bolt is a 35mm, might want to double check me...

So it is up to you..buy a new bolt which shouldn't be a whole lot and will look at be the most functional, or you can get a 6x35 mm bolt at a hardware store (get one longer than 35 and cut to 35mm with hacksaw if can't get exactly that length)

[sheweezy]

35mm in length*

and be the most functional*


love it when I cant talk

[honda400ex2003]

imo get the right one again since you got it out without doing any modifications. might as well make the side cover bolts match. :D

steve

[sheweezy]

x2.... Nothing looks better than OEM when it comes to the small stuff like that