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Message started by suzi-q on 12/26/18 at 16:44:47

Title: how do we remove the flywheel ?
Post by suzi-q on 12/26/18 at 16:44:47

how do we get this thing off? what tool do I need or is is there another way? thanks

Title: Re: how do we remove the flywheel ?
Post by verslagen1 on 12/26/18 at 16:56:34

rotor requires a special tool.
check with dave.

Title: Re: how do we remove the flywheel ?
Post by LANCER on 12/26/18 at 16:57:36

There are 3 special tools required to do the job. Don’t have the exact name and sizes off hand but someone will have the info at hand. I suggest you contact Dave, he is usually quick with answers like this.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/26/18 at 17:17:17

D A V E, help, please. how do we get this thing off? I blew the counter balancer out the front of the cases. and bent the balancer too. and broke the gear with the springs also. got another motor I hope to use the parts I need. thanks

Title: Re: how do we remove the flywheel ?
Post by GOF on 12/26/18 at 17:42:28

Is the other motor intact? Maybe save some time and effort and just install it?

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/26/18 at 17:51:03

someone ran it out of oil and wiped the cam and rockers. and took a toll on head too. thanks tho

Title: Re: how do we remove the flywheel ?
Post by Armen on 12/26/18 at 18:10:12

There are a few tools. Dave put them together as a rental package.
You might want to consider a light flywheel while you are there :-)

Title: Re: how do we remove the flywheel ?
Post by DieselBob on 12/26/18 at 19:05:36

The Russian's claim to do it without the special tool. Anyone tried this method? Admittedly, the translation leaves something to be desired.

rinat says:
05/18/2014 at 18:26

Good afternoon, I ask for your advice! I disassemble the engine Suzuki Savage LS650, I can not help but remove the generator rotor. Please tell me how to remove it? thank you in advance.
Reply

Aibolit says:
05/18/2014 23:03

In fact, the most correct would be to use a special puller. But it is possible to dismantle the rotor in another way. We unscrew 6 M8 hex bolts securing the rotor to the outer cage, shining a flashlight at the holes, and install the overrunning clutch gear so that the holes of the unscrewed bolts are opposite to its windows (you can simply use a probe to determine this: we scroll the overtaking as soon as the probe fail, then the window opposite the hole). In 3 holes out of 6 vacated (step 120 degrees), we tighten the M8 bolts with a length of 80 mm until they rest on the flywheel body, uniformly give a little tension (no more than 20 N * m), heat the rotor with a heat gun to 100 degrees. Check the tightness of the bolts, we reach it if necessary. Sharply strike the central part of the rotor with a hammer through an aluminum mandrel.

Title: Re: how do we remove the flywheel ?
Post by DieselBob on 12/26/18 at 19:15:02

Quote:

heat the rotor with a heat gun to 100 degrees

Presumably that's Centigrade. Or approximately 212 degrees F.

Title: Re: how do we remove the flywheel ?
Post by batman on 12/26/18 at 20:29:17

striking the rotor sharply or dropping it, can demagnetize and ruin it . It's best to buy or rent a puller.

Title: Re: how do we remove the flywheel ?
Post by Armen on 12/27/18 at 02:57:58

When all else fails, do it right.
Puller. Not a big expense.

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/27/18 at 03:58:01

The proper tools make it easy - the problem is they are a bit too expensive to buy when doing just one engine......and they are very heavy and somewhat costly to ship (unfortunately they don't fit in a small flat rate box. In addition to the puller for the rotor - you also need a deep socket for the flywheel nut....and a holder for the flywheel.

It sounds like you may have to remove the rotor from both engines....so you will need to do it twice.

Here is a link to the light flywheel/tool rental thread. If you don't want a lightened flywheel - then just look at the tool rental portion. The cost of renting the tools is just $20 and shipping is another $20 - but I require a $100 deposit. You will send me $120 and I will ship the tools to you, then when you return them I will refund you $80 (The $40 deduction is $20 for the rental - $20 for the cost of shipping them to you). The sad thing about all this is that it will end up costing you $60 - USPS makes $40 on this deal and I get $20 to cover the rental no the tools.

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1504271719/0#0

When separating the crank halves the left crank bearing is a snug fit on the crank......and it helps to use an assist - I have a flat plate that pushes on the crank and I can include that with the tool rental.

When you are doing this work - get the proper Suzukibond to use when assembling the crank halves and cylinder head cap. It works far better than any store bought RTV. The Suzukibond is black, if you have silver cases and want a grey colored sealer - get Hondabond or ThreeBond.

Where are you located....sure would be handy if you were local and didn't need to ship this stuff. It sounds like you have a big project ahead of you......making a good engine out of two damaged ones can be a big project.

If it is within your budget - this is the perfect time to upgrade the piston to a Wiseco, install one of Lancer's nitrided cam chains, and perhaps install a performance cam.....and do a bit of head work to clean up the ports!

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/27/18 at 06:50:49

hi all. anyone have a pic of this tool? how much are they? can we make one? what is the part # I love this bike . I may as well just buy one. I have two now. on is a ryca. the most uncomfortable bike I have ever sat on. is there a more comfortable seat? thanks

Title: Re: how do we remove the flywheel ?
Post by Fast 650 on 12/27/18 at 06:56:01

A good sized air or electric impact wrench will make removing the rotor and flywheel a lot easier too. Don't bother with the battery operated ones, they don't have the muscle to break the bolt and nut loose.The rotor bolt was installed with red loctite. Heat the bolt with a propane torch and it should come out easily with the impact.The woodruff key is in there tight too, be prepared for a fight getting those out. The woodruff key has to come out to get the flywheel off. And if you don't rent Dave's tools, you will need beg/borrow/buy a really deep (about 2 1/2 inches deep) 46mm socket for the flywheel nut.

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/27/18 at 07:17:03

1117180B4F13620 wrote:

Look at the link I provided....it has a photo of the tools you will need. A rotor puller, a 46mm deep socket to remove/install the flywheel nut, and a flywheel holder to keep the flywheel from turning while you loosen and torque the flywheel nut (I made mine from a socket and some angle iron).
http://i63.tinypic.com/2ljktg1.jpg

The stock RYCA seat has very minimal padding on the edges, and digs into your legs when you put your feet down....and not much padding in the center either. I rode for a couple years with the stock padding - but when we went on "all day" rides it was tiring.

I had a local upholstery shop add padding and make a new cover....it is a lot more comfortable now.

http://i61.tinypic.com/oq9m47.jpg

http://i62.tinypic.com/20a5c14.jpg

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/27/18 at 08:40:06

hi. I like the looks of your seat. what tank do you have on yours? thanks

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/27/18 at 08:45:23

1016190A4E12630 wrote:

hi. I like the looks of your seat. what tank do you have on yours? thanks

1972 Suzuki GT380/550.....claims to be 4 gallons.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/27/18 at 19:44:52

hi. I got the 17mm hex head bolt out. now the next nut is a 36mm. I saw someone say a 46mm. is this the same nut.? I have a 36mm socket that fits. I see a woodruff key in there. dose this have to come out first? if so, how do we get this out? thanks all

Title: Re: how do we remove the flywheel ?
Post by Fast 650 on 12/28/18 at 00:50:22

This is the 46mm nut (red arrow) that you have to remove.

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/28/18 at 03:10:35

Yep, that is the next nut to be removed. You can take it off easy with an impact wrench - but torquing it back in place requires you to hold the flywheel stationary.....that is what the tool does that bolts into the threaded holes in the flywheel.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/28/18 at 08:01:32

I have been calling the rotor the flywheel. duh. that 36mm nut has a woodruff key in there. should this come out first? thanks

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/28/18 at 09:02:52

The only thing under the flywheel nut is a spring washer......nothing else needs to come off to loosen the nut. The flywheel has splines holding it from turning on the crank.

Title: Re: how do we remove the flywheel ?
Post by Fast 650 on 12/28/18 at 09:05:01

Yep, the woodruff key will prevent the nut and flywheel from coming off so the key has to come out first. And it is a really tight fit in the crank. I had to use a hammer and a drive punch to get mine out. Be careful not to damage the slot in the crank when you are hammering the key out though. Woodruff keys are cheap if you beat them up too bad to use again, crankshafts are expensive.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/28/18 at 11:12:05

so do I drive the woodruff key inward? can't see it coming out. and then remove the 34mm nut? thsnks

Title: Re: how do we remove the flywheel ?
Post by Fast 650 on 12/28/18 at 13:37:33

You loosen the 17mm bolt a few turns then screw the puller onto the rotor. As you tighten the long bolt in the puller it presses against that 17mm bolt. Run the puller bolt down tight and give it a smack with a hammer and it should pop the rotor free then. Now you can remove the puller from the rotor, finish removing the 17mm bolt, and slide the rotor off.

Now you have access to the woodruff key to drive it out of the slot.
You will understand how this works immediately when you see the puller (that I am assuming you don't have yet).

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/28/18 at 16:13:12

hi. I could not see how this tool works. after searching it seems that the 36mm hex head nut with what looks like 50mm threads under it, dose not unscrew from the rotor as i was thinking. but it is used to screw the tool on. is this correct? then the smaller bolt on the tool does the pulling. is this tool a 50mm x1.5 R H female thread? if so my searches show the price for this tool is all over the place. I found this one. pit posse pp3271 50mm x 1.5 R H female thread. is this the size I need? thanks

Title: Re: how do we remove the flywheel ?
Post by Fast 650 on 12/28/18 at 18:50:36

That is right, and that is the correct part number for the puller too. The next hard part is finding a 46mm socket that is deep enough so you can get the flywheel nut off. Some people have found them with no trouble, but I couldn't find one anywhere when I needed one. I finally cut a short one in half and welded a piece of tubing between the two halves to make it longer.

Title: Re: how do we remove the flywheel ?
Post by Dave on 12/28/18 at 19:46:10

OK....now I see why I was confused about this thread.

It was fast 650 that posted the photo of the engine with the rotor and woodruff key already removed.

Suzi-Q has not gotten this far yet. ::)

Suzi-Q.....do you have a Clymer manual?

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 12/29/18 at 11:15:48

hi dave. I do have a Clymer manual. I have the tool on the way. what brand o f deep socket and just how deep do I need to get. I love tools. love this bike.

Title: Re: how do we remove the flywheel ?
Post by Armen on 12/29/18 at 17:38:41

I found a deep socket and squared up the face on the lathe to get a better purchase on the rather shallow nut.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 01/09/19 at 12:58:52

hi. just got the rotor puller and it was off I a flash. now how do I get the free spinning big gear off? to get to the flywheel nut? thanks

Title: Re: how do we remove the flywheel ?
Post by verslagen1 on 01/09/19 at 13:05:41

7C7A7566227E0F0 wrote:

hi. just got the rotor puller and it was off I a flash. now how do I get the free spinning big gear off? to get to the flywheel nut? thanks

Pull, it's not held on with anything.

Title: Re: how do we remove the flywheel ?
Post by suzi-q on 01/09/19 at 14:31:52

oh yea. thanks verslagen. that was easy now there is that 46mm nut I've been after. wow that flywheel looks bigger than it did in photos I've seen of it. and they say by cutting this thing down helps to make our bike quicker? i'm all in. thanks

Title: Re: how do we remove the flywheel ?
Post by Armen on 01/10/19 at 03:03:02

An object at rest, tends to stay at rest.
An object in motion tends to stay in motion.
Heavier flywheel is slower to accelerate than a light one.
So, the bike revs up quicker.
It also revs down quicker, so the bike should have more engine braking with a light flywheel.
And, if you think about it, with less flywheel weight, there is less gyroscopic effect, so the bike should be easier to turn.
Heavy flywheels are nice for a clock like idle, and holding an engine steady at any RPM (smooth highway riding). They mask a lot of poor tuning issues.
Having said that, no one has said the bikes were worse after putting in a light flywheel.
One way to find out ;)

Title: Re: how do we remove the flywheel ?
Post by Dave on 01/10/19 at 03:56:45

Here is how you get one:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1504271719/0

You aren't going to need to rent the tools......so you can save that cost.

Since you are so far into the engine and have to take the flywheel off anyhow....it would be a shame not to upgrade to the lighter flywheel.

It will only cost you $57.15 once you have returned your large flywheel core to Armen:

Title: Re: how do we remove the flywheel ?
Post by Suzuki86prince on 11/02/22 at 14:23:47

Hi everyone. Just a really quick question.
I’m looking to buy a flywheel puller. But I’ve seen two different ones being sold under Suzuki savage. One is size 50/1 and the other is 30/1 I am wondering which size is proper for this job

Title: Re: how do we remove the flywheel ?
Post by verslagen1 on 11/02/22 at 16:32:58

787E7162267A0B0 wrote:

Yes this is the tool