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Post by paulpg36 on Jun 9, 2023 15:25:52 GMT
I am trying to remove the flywheel so that I can remove the stator as I think it is kaput and want to send it to Rex's for testing.
I have looked at various threads on here and there is a suggestion to use the oil cover bolt. However, I decided against this as did not want to potentially damage it so I bought a puller bolt off ebay. I duly removed the centre bolt after blocking the flywheel. I then inserted the puller bolt and tightened it clockwise whilst trying to hold the flywheel in place. I tightened it as far as I could but not sure what to do now? Is it supposed to come off or what?
Any help would be very much appreciated.
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Post by duffer on Jun 9, 2023 15:42:30 GMT
Smack the end of the puller bolt with a hammer. Then nip it up a bit and hit it again...repeat...
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Post by paulpg36 on Jun 10, 2023 6:49:33 GMT
Thanks, Duffer. I have tried your suggestion but without success. Maybe I'm not hitting it hard enough (using a rubber mallet) as I don't want to risk damaging anything. Now I can't even remove the puller tool as it is now screwed in solid. I suppose what I don't understand is what is holding the flywheel in place? Is it just magnetism or something else?
I am also having a problem holding the flywheel still and wondered what is the best way to do this?
Many thanks, a very frustrated Paul.
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stevegbr
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BIRMINGHAM
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Post by stevegbr on Jun 10, 2023 7:12:15 GMT
put a photo up so we can see what you are doing please.
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Post by paulpg36 on Jun 10, 2023 7:54:45 GMT
put a photo up so we can see what you are doing please.   A couple of photos. One shows just the puller bolt in place and the other shows how I'm trying to secure the flywheel in place but not very successfully. |
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Post by buster on Jun 10, 2023 11:42:39 GMT
posh tool really helps and an oil filter bolt from silvers (17mm head). holding it steady with the posh pliers I then give the ratchet a good firm smack with the palm of my hand.  |
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willy3pigs
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Post by willy3pigs on Jun 10, 2023 12:55:27 GMT
Interesting how different my experience of removing the generator rotor is from yours Buster. I tried the oil filter bolt method and soon thought better of it, as the amount of torque needed to achieve success was way more than I considered was good for the bolts reuse for its intended purpose. The generator bolt should be torqued to 70-90ft-lbs according to the manual, and on both my bikes, I have found that was approximately the force required to shift the rotor. I have a 30" length of aluminium angle with lugs set up for the 400 Hitachi generator on one end and lugs for the 250 Denso type at the other end. Pics below. To stop the crank turning with 70-90 pounds of torque on it, I would need to enter a phone booth, spin round a few times, and exit with my red undies over my bright blue trousers to equal what you can manage with your posh pliers..    |
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Post by buster on Jun 10, 2023 19:14:48 GMT
the posh pliers are specifically designed for that purpose, I have come across a seriously brutal one on a 250 engine (the breaker I bought it off sold it with the stator on for £70) I actually (I'm ashamed to say) snapped the cam chain getting that particular one off. same tools though, posh pliers, breaker bar instead of ratchet, silvers oil filter bolt and a nylon hammer to keep tapping around the mag wheel.
I honestly thought you were joking with the torque figures or it might have been a misprint, but no it turns out your right and in my opinion its completely unnecessary, if the tapers are clean and the woodruff key's a good fit I simply cant see the need, the mag wheel spins anticlockwise and the bolt tightens clockwise, a good firm nip up and nothings going anywhere, at least I'v never had any problems doing them like that
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Post by paulpg36 on Jun 11, 2023 6:49:59 GMT
When I was researching this subject I came across a post in 2015 when someone was complaining about paying £40 to get a flywheel removed by a dealer. I would gladly pay £40, probably more today, to have it removed. Indeed, I have already spent £20 on the puller tool which doesn't pull although I'm probably using it incorrectly.
Would a strap wrench be any good to hold the flywheel in place or where can I get the "posh pliers" Buster was using? I do not have the metal working skills or tools to make something like Willy's solution. Any other thoughts on what to do next would be very much appreciated.
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Post by buster on Jun 11, 2023 8:22:03 GMT
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Deleted
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Post by Deleted on Jun 11, 2023 8:52:40 GMT
FWIW I suspect you are being a bit gentle ! I would be v wary of locking up the flywheel against the generator windings like that .
Tighten the puller bolt as tight as you can and hit the end of it with a steel hammer , you will then find you can tighten a little more - repeat until it come off with a bang .
With a T bar type tool instead of a ratchet on the socket you can hit the end with your rubber mallet to tighten the puller against the inertia of the engine .
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Post by marktrower on Jun 11, 2023 15:06:29 GMT
never failed yet to remove a taper , there are hammers and .hammers,a good lump hammer are a good tool to have they have some good weight behind them and a large contact area so you can give a good even blow.the tool buster has are very good a home made tool are just as good but are not universal .but the best tool i have found for rotors is the correct tool my impact gun that gets 90% off and the rest pop off with a firm blow to the end of the puller.i have a very good compressed air gun that has never failed yet on anything but for bikes this is all i need £50 of geek site that was about 6 years now so would have gone up in price good battery life .tighten up give it a good blow and tighten it will come .its the shock through the shaft that overwhelms the friction  |
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Post by paulpg36 on Jun 11, 2023 20:13:45 GMT
Many thanks to everyone who gave me advice on removing my flywheel. It came off quite easily once I gave it a few hard bangs with a hammer although there was no pop although maybe it was drowned out by the noise of the hammer. The next challenge is removing the screws which are very tight. I have some JIS screwdrivers but at the moment I can't move any of them!
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Deleted
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Post by Deleted on Jun 11, 2023 20:50:19 GMT
Good news . Again with the screws "controlled brutality" is the way to work , hit the ends with a hammer to hopefully loosen a bit then go straight in with the impact driver before they have chance to round off etc .
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Post by paulpg36 on Jun 15, 2023 18:21:24 GMT
I'm starting to lose the will to live on this subject. As previously reported, I got the flywheel off but then could not move any of the 5 screws using the JIS screwdrivers I already had. I then ordered some JIS bits for my impact driver, the sort you hit with a hammer which did not loosen them at all. I then decided to order a power impact driver not realising only certain bits with a special end fit in it. The JIS bits I bought earlier in the week did not fit.
I duly went on Amazon to try and get some JIS impact driver bits. I found some in the US for about £28 but delivery would be end of June to 4 July! I just could not find any in the UK or anywhere else. I was reluctantly willing to pay £28 but not for delivery in July. This is costing me an absolute fortune and I was wondering whether anyone had any suggestions on what I should do. Should I risk the non JIS bit which came with the driver on one of the screws or know of anywhere in the UK where I could get the correct driver JIS bit? Any help would be very much appreciated. Paul
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