OK, what's the secret to getting the clutch rubbers in?

[clanger9]

Hmm, just had a quick look at the new rubbers for my clutch shock absorber:



It looks like it's going to be a very tight squeeze to get them in!
Any tips? Do I drive a wedge in the gap? Squash them in a vice beforehand? Warm them up to soften them? Looks like this could take a while...

[ajscomboman]

The easiest way is to use an old mainshaft held in a vice and using a clutch locking tool lever it open and slide the small rubbers in. You can do the same using the shaft in situ on the bike but will need a extra pair of hands to assist as someone will have to push on the rear brake pedal after putting the bike in gear to stop it from moving.

[clanger9]

Thanks, that method makes sense. I don't have a spare main shaft, so I'll have to do it on the bike.

"More leverage". That's what I need!

[ajscomboman]

Make a simple locking tool using a plain and friction plate welded/bolted together and attached to a suitable bit of bar. There should be a picture of one in your manual. That'll get you all the leverage you need.

[clanger9]

Ah yes, I wondered what that was a picture of in the manual. Easy to make!

[clanger9]

Ahh, it seems I don't have an old friction plate lying around - just a plain plate with external ears. I need a one with internal ears.

Is the "official" tool part number 23441? It's not too expensive, so I might just need to order one of those...

[clanger9]

Update: I made a suitable tool out of two clutch plates and I was finally able to get the new rubbers in.
It took a surprising amount of torque to squash the rubbers far enough (I couldn't hold it on the rear brake...), but at least they're in now.



Thanks all for the help & advice!