Can't remove pinion gear

Background: I noticed that the chain tension varied greatly as I turn the rear wheel by hand. Replaced one of the rear bearings, the one that looked like it was shot (the other looked good), but that didn't fix the chain tension problem. Took off the clutch housing and spun the clutch by hand. The drum spins straight and quite freely. The pinion wobbles. I figure it's either bent or it was crossthreaded at the factory.

I tried unscrewing the pinion, but so far haven't been able to. I clamped the pinion in the vice and tried to turn the drum using heavy-duty needle nose pliers through the oval openings, but it just doesn't budge. I tried heating up the drum with a torch. Nothing. At this point I have applied all the force that I'm capable of and am beginning to think that the pinion is simply cross-threaded.

Any ideas/advice? Replace the whole clutch housing?

I posted some instruction for removing the pinion for someone else here:

7 or 8 front pinion?

It will give you a lot more leverage. There are also instructions for taking the whole thing apart if you search. Pinions are installed with a primitive locktite, so heat it just before you try to remove it.

Did you check your rear sprocket? It can get off center and cause the problem you describe.

It is NEVER the front pinion. It is always the rear sprocket. To verify this spin the wheell untill it gets tight. then put a sticker on the sprocket twards the top. now everytime it gets tight the sticker will be in the same spot. if it was the pinion it would get tight and loose TEN trimes with one rear wheel spin.

Your welcome.

What you say makes perfect sense, however... After I took off the chain and spun the clutch drum by hand I can see the pinion gear wobble a little (enough to be noticeable with the naked eye). Then I spun the rear wheel and could see the rear sprocket stay very steady - no wobble at all. Now this is of course without any chain tension on it. Could it be that the variance in chain tension be attributed to the bent pinion gear and a twisted chain (however the chain off the bike looks fine). Again, the rear sprocket looks good, the wheel bearings look good. What else can it be?

Thanks for all the advice.

Try the sticker thing, really it is the rear sprocket. The rear sprocket doesn't have to be off by alot to cause this. and the front pinion does have to be off by alot to cause this. a little noticable wobble in the pinion is normal.

When they put it together from the factory they used some heavy duty locktite. Mine wouldn't even come off even with heat! So I got ****ed off and took a really big pair of pliers and wrenched as hard as I could, guess what it came right off weird. Of course I ruined the 6 tooth but it didn't matter because I was going to replace it any way with a 7. Then I bought another stock clutch bell with a 6 tooth sprocket in case I wanted that size later in life. Now I have what ever I need!
Hope this helps!!!!

To ewerybody; I had my pinion problem to but the prob. was that the pinion was welded on the inside of the clutch drum. Yes it was punktured twice with MIG welder! I have had a hard time grinding that two little welds off. Howewer there was no loctite on the thread of a pinion. Hope this helps you guys.

not sure why this old thread got brought up again...? lol a simular thread about pinion gears was made a few days ago with some helpful hints. FOUND BY CLICKING HERE!

the heavy duty locktite you refer to is the white epoxy bond. pliers onto a 6t WILL damage the teeth of the pinion gear! if you used the gator grips I mentioned in the other post about removing pinion gears, this would have not happened!!!

yes a few stock clutch bells do come welded at times. I came through a few "yomer" made cags that had welded clutch bells that I sold before. if the pinion needed to be changed, you would either have to buy another clutch bell housing and pinion or grind down the spot welds like you've mentioned.

Removing so easy with 6 point socket and an impact gun. If you don't have all that, take it to a auto shop, they will do it for free. 3 seconds.

true, impact gun is much easier but to bring your compressor to a track would be a hassle. even if you had one of them electric impact guns, it isn't easy finding an outlet sometimes...? I fit what ever I can in my tool box for thoes days in the pits when I don't have access to my garage power tools.