GK800 Clutch replace

Posts: 9 · Joined: 14 Apr 2008 Posts: 9 Pictures: 0

Thanks for all of the post guys. I am confident that it is not the hydrolic system at this point. I tried to manually push the lever closer to the tranny and it doesnt help enguage. Anyway, does anyone know if a suzuki swift clutch will work. I found one at a Shucks and it is like 1/3 the price that the dealer wants.

I am actually working on it now, but I cant seem to get the drive shaft out of the differential. I was assuming that it would just simply slide out. Is ther some sort of snap ring holding under the plastic seal? Do you need to remove the black seal that is pressed into the differential? Any other tips or tricks would be nice.

Posts: 956

On mine it just slid right out, but there are some differences on different buggies, so maybe there is some kind of a clip. Good luck. Van

Posts: 342

Yes there is a spring clip on the end of the axle, put a bar on both sides of the cv between the trany case and the cv joint then pry it out. No a swift clutch wont work the splines are differant. You will also need to build your own disc alignment
tool for the install, I have never found a tool with a small enough tip to fit in the pilot bearing .Good luck.

W.C.

Posts: 1911

Would an axle slide hammer tool work to get the half shafts off? It seems like there is a chance of causing damage with pry bars.

Posts: 309

I have removed many of axles in the past with these buggys and have found the for sure way is to use the axle as a slide hammer. The more even the pull or pop is the way to go. Lower the control arm until the axle comes out of the hub then start popping or pulling the axle straight and hard. This will align the inner stub axle clip more evenly compared to prying. Wink

If that doesn't work just cut and weld it. Just kidding, it should work.

Posts: 342

All great sugestions , I guess I have never seen one stuck.
A light push on the bars and the axle pops rite out, but I have read on here about some problems with removal. Its way more typical a guy would have two small bars that an axle puller I guess is what I was thinking.

W.C.

Posts: 200

Posts: 956

I guess I got lucky guys. Once I got my wheel off I just grabed the axle a pulled, and it poped right out. No prying needed. Van

Posts: 9 · Joined: 14 Apr 2008 Posts: 9 Pictures: 0

I finally got the axel off. I ended up using the slide hammer technique. Prying did not work at all. We yanked on the axel for about an hour with no luck, then out of the blue a single yank got it out. Crazy. Anyway. The clutch plate is basically gone, there are shreds everywhere.

P.S. I had to remove the exhaust to get the tranny housing out.

Does anyone know where the best place to order the plate from. I tried a Suzuki Swft clutch, but the spline shaft is bigger on the swift.

Posts: 1273

Try Dave at awsomebuggy.com
I think he may carry the replacements.

Mick had a shop cut one to fit I think.

Chris