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General Category >> Rubber Side Down! >> How do I remove the flywheel?? (with pics)
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Message started by FollyRob on 06/25/07 at 14:17:02

Title: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/25/07 at 14:17:02

After dealing with the no-good rotten stealership and having them try to rip me off I decided to take on the project of changing the starter clutch myself. I consider myself quite mechanically inclined but this is my first motorcycle. I already have the new parts, a new starter clutch, idler gear, and gasket all from mrcycles.com. They were great to deal with and have good prices on OEM parts.

First I took off the left side peg and clutch in order to get to all of the bolts on the generator case. After that I removed the genny case and then on to the flywheel nut. This proved to be quite difficult to get off because whoever put it on last used quite a bit of loc-tite. However with two men and two four foot breaker bars we finally got it. Now I just need to get the flywheel off. But how? Can any of you gearheads on here help me out? Also, is there anything I should be prepared for or look out for when removing the starter clutch assembly and re-installing a new one? Any help would be appreciated and I included a photo for reference.

Also, if anyone has any parts they want to sell or just get rid of I am in need of one. The small gear attached to the starter motor (top middle of pic, it is kind of chopped off) on my bike is quite worn and I could use a new one. An OEM replacement is too expensive but do any of you have one used that is in good shape? Help with that would be appreciated too.

Thanks ahead of time! Once I figure this all out I'll do a step-by-step with pics in the technical section for everyone.

http://imgplace.com/directory/dir4703/1182805463_9675.JPG (http://www.imgplace.com)[/url][url][/url][url]

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/25/07 at 19:15:24

Anyone?

Title: Re: How do I remove the flywheel?? (with pics)
Post by Kropatchek on 06/26/07 at 04:25:49

You're on the right track.
Now you got the flywheel ~~nut~~ bolt out you can screw it back in and back-off a few threads.
To remove the flywheel ( Suzuki calls it the rotor) you need a special puller. The puller screws on the large thread just visable behind the large hexagon on the rotor.
The rotor has a woodruff-key to fix the position on the crankshaft.
Sorry can't be of much more help! :-[

Title: Re: How do I remove the flywheel?? (with pics)
Post by mpescatori on 06/26/07 at 05:04:20

I know what I would like:
a flywheel at least twice as heavy as the standard OEM part.

My first motorcycles were Italian singles, a Ducati 450
http://www.ducatiscrambler.com/infotecniche/SCR-1serie.jpg

and a Guzzi 500 Falcone,
http://www.devce.demon.co.uk/falcone/Aug15$05.jpg
and both were known for a heavier-than-average flywheel; the result was an engine that would idle at... 60 rpm :D and pull away smoothly from 1000 rpm 8)

The Savage, on the other hand, seems to have a very light flywheel, which may be very nice on a high-revving competition single, but is possibly a liability when cruising on twisty local roads

Title: Re: How do I remove the flywheel?? (with pics)
Post by Dr_Jim on 06/26/07 at 07:56:49

Title: Re: How do I remove the flywheel?? (with pics)
Post by Crusher0964 on 06/26/07 at 12:38:20

I made a puller out of a piece of 2" angle iron with two holes that match up to the rotor bolt holes and one in the center or you may be able to use a steering wheel puller...

Title: Re: How do I remove the flywheel?? (with pics)
Post by Rockin_John on 06/26/07 at 13:38:56

mpescatori wrote:

Back when I was 12, that 450cc model Ducati was the bike of my dreams. The only motorcycle I'd ridden to that point was a 250cc Ducati Diana (capable of over 100mph)!
http://catoosatrading.com/images/vehicles/250cc_ducati_diana.jpg

A year later I was actually legally licensed to ride a Honda CL-90 with a factory 5HP restriction plate.

As for "pullers" I've built all but two I've ever owned for myself. The two I bought would have required that I buy thread dies more expensive than the puller I would have built. I've always done things the least expensive way possible... With a few rare exceptions. A couple of examples: I don't roof houses, and I don't do car/truck exhaust systems.

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/27/07 at 14:38:08

Ok, I can go ahead and make a puller out of 2" angle iron but what in the heck do I do with it once I have made it? I understand how to make it but how is it used?? Do I need any other hardware?

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/28/07 at 14:46:00

does anyone know? or possibly know of other ways to get the thing off? I am ready to ride this bike and this is the only thing holding me up!

Title: Re: How do I remove the flywheel?? (with pics)
Post by vroom1776 on 06/28/07 at 14:51:39

do you have a service manual? going that far itnot he engine w/o one isn't a good idea.

Title: Re: How do I remove the flywheel?? (with pics)
Post by grim on 06/28/07 at 16:36:14

Um...I didn't have to remove the flywheel to replace the starter clutch.. ..so you may be overdoing it. But if you have to do the removal.....well...good luck without the puller. try and rent one....? and have fun replacing the clutch discs too...hope you have the whole clutch assembly

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/29/07 at 15:20:16

I have the whole starter clutch assembly. How in the heck would you replace the starter clutch without removing the flywheel/rotor? The starter clutch is right behind the flywheel! I just need to figure out how exactly to make that puller tool and how to use it once I have made it.

Title: Re: How do I remove the flywheel?? (with pics)
Post by grim on 06/29/07 at 18:50:50

Pull on the starter clutch. it slides out. I had to find the "right" spot/rotation of the rotor/flywheel. It is a tight fit. First pull on the clutch out, then rotate the rotor, pulling on the clutch outwards. it should pop out.

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/30/07 at 07:27:25

That doesn't make any sense to me.

Title: Re: How do I remove the flywheel?? (with pics)
Post by grim on 06/30/07 at 17:52:17

you have the clutch behind the large rotor thing. but there is still space between the two. The only thing holding the clutch in place is the cover (which you removed). so just take hold of the little clutch and pull. it will stop because you hit the large rotor thing. then start rotating the large rotor thing while pulling on the clutch at an upward 45 degree angle. It worked for me.

Title: Re: How do I remove the flywheel?? (with pics)
Post by grim on 06/30/07 at 17:58:01

http://w2.bikepics.com/pics/2007/04/05/bikepics-854671-800.jpg

Pull on the little clutch....pull a little up while pushing the larger rotor thing down....and rotate little by little....

if not....you lost nothing....and you still have to pull the rotor thing

Title: Re: How do I remove the flywheel?? (with pics)
Post by FollyRob on 06/30/07 at 18:37:03

That is why I didn't understand. I am not trying to get the "little clutch" off. I need to get the big clutch off. The one directly behind the rotor.

Title: Re: How do I remove the flywheel?? (with pics)
Post by grim on 06/30/07 at 22:04:56

:D

nevermind I was refering to limter assy....sorry....you need a puller.....heehee

Title: Re: How do I remove the flywheel?? (with pics)
Post by kamelryttarn on 08/28/19 at 23:16:36

Stupid question but it's better to ask then break something. What "direction" is the flywheel nut? Is it a left hand thread?

Title: Re: How do I remove the flywheel?? (with pics)
Post by Fast 650 on 08/28/19 at 23:39:11

Rotor and flywheel both use right hand thread fasteners. And you will need a really deep socket for the flywheel nut.

Title: Re: How do I remove the flywheel?? (with pics)
Post by kamelryttarn on 08/29/19 at 02:15:42

Thanks! I bought a cheap "deep" 46mm socket. Not sure HOW deep it is since I haven't got it yet but I hope it's enough :)

Title: Re: How do I remove the flywheel?? (with pics)
Post by batman on 08/29/19 at 04:47:31

You NEED to buy a Clymer repair manual AND READ UPON IT ! You NEED to have the special puller and socket!(Dave may have the tools you can rent from him) You NEED to be very careful pulling the rotor ( any sharp blows, or dropping it ,can demagnetize and ruin it. BIG $$$$$$ to replace it! IF you can find one! ) Knowledge is power! You can't fix everything with a hammer! (some members have changed to lighter flywheels that sit behind the rotor , do some research ,they should provide pictures and give you some idea of what your attempting to do).

Title: Re: How do I remove the flywheel?? (with pics)
Post by Armen on 08/29/19 at 06:01:48

FWIW, these bikes have a WAY heavy flywheel. We've played with lighter flywheels, and even the lightest one is enough.
As for having the bike idle at 60 RPMs, not a great idea as there will be almost no oil pressure.
Dave has a kit of tools to remove the rotor/flywheel.

Title: Re: How do I remove the flywheel?? (with pics)
Post by kamelryttarn on 08/29/19 at 07:03:08

Shipping the tools needed to Sweden would most likely prove way too expensive. I received the flywheel puller yesterday and I think the 46mm socket will arrive next week. The tool needed to lock/hold the flywheel while loosening the nut I will try to manufacture myself. I am NOT a fix-everything-with-a-hammer-kind-of-guy and I have a fair grasp of the different steps involved.

Title: Re: How do I remove the flywheel?? (with pics)
Post by Armen on 08/29/19 at 07:20:13

The 46mm nut is pretty shallow. To minimize the chance of rounding it out, square up the face of the socket on a lathe.

Title: Re: How do I remove the flywheel?? (with pics)
Post by kamelryttarn on 09/22/19 at 11:35:25

Not entirely sure if I should post this in this thread or start a new one, but I have some of the tools needed now and the Clymer manual as suggested but when I drained the oil today I noticed I may have trouble getting to one of the bolts of the left side cover. Is this some kind of after market forward control the previous owner installed?

Title: Re: How do I remove the flywheel?? (with pics)
Post by verslagen1 on 09/22/19 at 11:41:37

even if it was stock, you need to remove the kickstand/peg mount to get it off.

Title: Re: How do I remove the flywheel?? (with pics)
Post by DragBikeMike on 09/22/19 at 15:02:06

That side stand is off a Harley. The Motor factory refers to it as a "Jiffy Stand". Pretty cool. ;D

Your forward controls are obviously not stock. Versy is absolutely correct, you gotta get the stand and controls off to gain access to the alternator cover fasteners. Make sure the motorcycle is well supported (preferably with tiedown straps) before you remove the stand. You will be applying a lot of force to break loose and tighten the alternator and flywheel. Don't want the scooter tipping over on you.