The work on the XL250R reached the part where the clutch basket had to be removed. Te shape of the nut asked for a special tool or a red neck approach. No luck buying one and not being a big fan of the red neck approach I opted for the third solution – build my own special tool. Not the smartest if you use it only once but if more XL250R`s are down the waiting list then it starts to make more sense.

Step one – take a imprint of the nut with silicone.

Step two – make a mould out of gypsum

Step three – without picture, done by my father, die cast the part out of s strong alloy.

Step four – the special key fits on the nut and in a 27 socket wrench. The size fits the1/2 air wrench.

Step five – make some adjustments with paper.

Step six – the nut was open in five seconds. It is reusable, it is not the red neck method and at re-assembly I will be able to use the torque wrench to tighten the nut.

The rest of the work on the Honda XL250R in a future post. If still no clue, the red neck method is with a hammer and screw driver. Judging by the sings the engine was under this treatment at least once.