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

grim Junior Member Offline Posts: 92 San Jose,CA Gender:	Re: How do I remove the flywheel?? (with pics) Reply #15 - 06/30/07 at 17:58:01 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
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FollyRob Ex Member	Re: How do I remove the flywheel?? (with pics) Reply #16 - 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.
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grim Junior Member Offline Posts: 92 San Jose,CA Gender:	Re: How do I remove the flywheel?? (with pics) Reply #17 - 06/30/07 at 22:04:56 nevermind I was refering to limter assy....sorry....you need a puller.....heehee
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RocketScienceSmurf Senior Member Offline SuzukiSavage.com Rocks! Posts: 268 Sweden Gender:	Re: How do I remove the flywheel?? (with pics) Reply #18 - 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?
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Fast 650 Senior Member Offline SuzukiSavage.com Rocks! Posts: 388 Valrico, FL Gender:	Re: How do I remove the flywheel?? (with pics) Reply #19 - 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.
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RocketScienceSmurf Senior Member Offline SuzukiSavage.com Rocks! Posts: 268 Sweden Gender:	Re: How do I remove the flywheel?? (with pics) Reply #20 - 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
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batman

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Re: How do I remove the flywheel?? (with pics)
Reply #21 - 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).

« Last Edit: 08/29/19 at 17:33:24 by batman »

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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1431	Re: How do I remove the flywheel?? (with pics) Reply #22 - 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.
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RocketScienceSmurf

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Re: How do I remove the flywheel?? (with pics)
Reply #23 - 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.

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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1431	Re: How do I remove the flywheel?? (with pics) Reply #24 - 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.
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RocketScienceSmurf

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Re: How do I remove the flywheel?? (with pics)
Reply #25 - 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?

DSC_1459.png

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28752 L.A. California Gender:	Re: How do I remove the flywheel?? (with pics) Reply #26 - 09/22/19 at 11:41:37 even if it was stock, you need to remove the kickstand/peg mount to get it off.
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DragBikeMike

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Re: How do I remove the flywheel?? (with pics)
Reply #27 - 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. Grin

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.

Knowledge is power.

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