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How do I remove the flywheel?? (with pics) (Read 275 times)
FollyRob
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How do I remove the flywheel?? (with pics)
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.



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FollyRob
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Re: How do I remove the flywheel?? (with pics)
Reply #1 - 06/25/07 at 19:15:24
 
Anyone?
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Kropatchek
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Re: How do I remove the flywheel?? (with pics)
Reply #2 - 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! Embarrassed
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mpescatori
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Re: How do I remove the flywheel?? (with pics)
Reply #3 - 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


and a Guzzi 500 Falcone,

and both were known for a heavier-than-average flywheel; the result was an engine that would idle at... 60 rpm  Cheesy 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
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Dr_Jim
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Re: How do I remove the flywheel?? (with pics)
Reply #4 - 06/26/07 at 07:56:49
 
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« Last Edit: 12/23/07 at 14:47:32 by Dr_Jim »  
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Crusher0964
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Re: How do I remove the flywheel?? (with pics)
Reply #5 - 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...
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Rockin_John
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Re: How do I remove the flywheel?? (with pics)
Reply #6 - 06/26/07 at 13:38:56
 
mpescatori wrote on 12/31/69 at 16:00:06:
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


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)!


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.
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FollyRob
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Re: How do I remove the flywheel?? (with pics)
Reply #7 - 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?
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FollyRob
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Re: How do I remove the flywheel?? (with pics)
Reply #8 - 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!
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vroom1776
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Re: How do I remove the flywheel?? (with pics)
Reply #9 - 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.
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grim
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Re: How do I remove the flywheel?? (with pics)
Reply #10 - 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
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FollyRob
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Re: How do I remove the flywheel?? (with pics)
Reply #11 - 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.
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grim
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Re: How do I remove the flywheel?? (with pics)
Reply #12 - 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.
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FollyRob
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Re: How do I remove the flywheel?? (with pics)
Reply #13 - 06/30/07 at 07:27:25
 
That doesn't make any sense to me.
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grim
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Re: How do I remove the flywheel?? (with pics)
Reply #14 - 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.
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