I am reinstalling the clutch with the Clymer manual, and had to use a 3 armed puller to remove it, and pushed the pilot bearing bush in by about 5 mm. I found this post about it https://www.k100-forum.com/t15657-solvedmoved-pilot-bearing-bush but the answers seemed to vary from its OK as long as it's not too far back, to tapping it and replacing it. Can you tell me which is the best solution?

One of the responses suggested using a harbor freight Bush puller, but the link was dead. Looks like this is similar?

https://www.harborfreight.com/two-jaw-pilot-bearing-puller-58209.html

At the bottom of the thread will be a very hard O-ring which needs to be removed before attempting to remove the clutch basket. It will not come out easily and needs to be dismembered using a sharpened screwdriver to cut it up into a few pieces. After that has been removed the basket will slide of easily, if you use a puller all that will happen is at best a distortion of the basket and worst breaking it.

I was able to get it out with the puller per the clymer manual, but when I was putting it back in I noticed the bushing was recessed. It was flush before, here's a before pic:

A couple of options. You can get special pullers for that with an L shaped end that fits behind the bush, which will pull it back out without causing damage. You could get a suitable bolt and cut half the head off, creating a similar L shape, put it, in fill the hole with something, then pull it out, but then you would want to replace the bush. Or do a similar thing with a heel bar.

daveyson wrote:A couple of options. You can get special pullers for that with an L shaped end that fits behind the bush, which will pull it back out without causing damage.

Is this the tool you are referring to?
https://www.harborfreight.com/two-jaw-pilot-bearing-puller-58209.html

No, it says half an inch, that's too big.

I'm thinking something like this:

https://www.aliexpress.com/

Not sure if 6 mm is ok, you need to measure it.

Sorry that Link didn't work, I'll try again later.

I can't get it. At AliExpress is a heavy duty bearing puller fixture 6 to 19 mm add. It's $5.52. it has a short video for how to use it. It's for use with a slide hammer.

Hopefully someone else will attach it to a post.

The bushing should be 6mmX12mmX12mm. If you intend to reset it flush, you'll need a blind hole bearing extractor—otherwise known as a puller. The extractor will need a collet or jaws that will fit into that 6mm hole. The set in the photo below has a 5.8mm collet that would work. You can use either the supplied slide hammer or the supplied counterstay. Call NAPA, Pep Boys, AutoZone, etc. Some times they lend such tools at no cost if you leave a security deposit using a credit card and return the tool undamaged.

Let Chuckles show you how in the video below. You could use the slide hammer to knock it upwards to be more satisfactory for you.

Here's a set at AliExpress that has a 5.8mm collet. Its price has been marked down 2%!

 

These are great tools but be careful when operating. Do NOT steady the tool with your left hand on the shaft below the upper end handle. Why? When sliding the moveable weight upwards using your right hand with considerable force to hit the end handle, if your hand is in the way, you will injure it. Easy to do when focussed on getting a bearing out.Keep you left hand completely on the upper handle

True, be careful.

Sometimes when it's unusually difficult you can resort to a special tool. Dunno the American term for it, it's an attitude adjustment tool, and it looks like this:

https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcRsLOGwMEu0WCalGYndB1peKwXx7nLeEY0Vq6TWfVaaD3zXjqxKImCKxUQ&s=10

I haven't done this job on a K100, but I discovered a way to remove a bush from a blind hole.
Method is to cut up some solder wire into small pieces and fill the cavity with them through the bush. Pieces of lead should work too.
Then use a steel rod which is a sliding fit in the bush, and tap with a hammer, whereupon the bush will be pushed out from behind.
Some people use bread or grease instead of solder.
I did this to remove a split roll pin that had broken flush with the surface of a blind hole.

daveyson wrote:Sometimes when it's unusually difficult you can resort to a special tool. Dunno the American term for it, it's an attitude adjustment tool, and it looks like this:

https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcRsLOGwMEu0WCalGYndB1peKwXx7nLeEY0Vq6TWfVaaD3zXjqxKImCKxUQ&s=10

The part number for this tool is No.1

Is the bush in a blind hole?
My first thought was the classic tip to fill the hole with grease, then tap in a close-fitting drift to push the bushing out with pressurized grease behind.
I was impressed how slick this worked the first time I needed to try it.