The bolt type puller is the only recommended way to remove the flywheel without damaging anything. Be sure to back off the pullers' center screw when mounting puller. 4) a torque . Can you use heat to remove a flywheel? Now screw the puller into the flywheel as far as it will easily go. If no puller is. Dismantle the spark plug and inspect it. When all else fails, heating the flywheel can often do the trick. Ian, The JAP 2A manual I have describes undoing the bolt to remove the starter. first loosen and unthread the lock bolt. Make sure this fits by entering your model number. Basicly the first thing to do is take the cap and magnet off. How to Remove a Mercury Flywheel Unlatch the clips that are used to secure the cover and take the cover off the motor. To do this, you must somehow prevent the flywheel from turning while you are trying to remove the nut. Get it as soon as Fri, Jun 3. . Sep 16, 2020. If there is a hole after removing the mag bolt, you have an inny. put a 2 inch long bolt in and you have your puller. I think the nose bit bottoms out in the hole so the 100mm bit doesn't contact the end of the taper. A dry candle with a slight brown tint of the electrodes can be considered serviceable. Report abuse. `10x1.25 pitch. Several days of penetrating oil and banging the puller didn't work. available the manual states that the flywheel should be "grasped firmly and. The puller is a new design with a small hole in the center that allows the user to remove the plug in the power tool. And flywheel puller magneto enabling you to remove and replace the worn out pulley in the original vehicle without damage or damage. An easy way to remove The flywheel on Kawasaki atvs and 3 wheelers without a specialty puller. Reactions: Also drill a hole on centre of the 2.5" metal piece (head of the bearing puller . Requires 19mm wrench or socket Tool height: 57mm without the threaded bolt Threaded Internal: 27mm Threaded External: 26mm This tool is a must have for the pulling of the . #2. Once thats done stick the magnet to a heavy piece of steel (1/4 inch plus) this keeps it from loosing its charge. If there is a hole after removing the mag bolt, you have an inny. Having to remove, and replace the bearing perhaps several times to get the shimming correct tells me that the services of a machine shop are need to properly make an accurate puller. Tighten the puller and wait for the "pop". However, with them, and on a K . Thought I was going to either break the flywheel or the puller. I think the nose bit bottoms out in the hole so the 100mm bit doesn't contact the end of the taper. This tool is another one of those must have tools if you are a small engine mechanic working on the Chinese brands of ATVs. Wouldn't get creative unless you need to. The puller shown below is one that I made that is somewhat universal for these size of motors as the 3 bolt holes are slotted to accommodate different hole patterns. Insert two bolts into the threaded holes on top of the flywheel. I was wondering if it is possible to remove the flywheel with a two-arm puller. When installing a new electrical module on the engine, the magneto gap must be adjusted. leave a little space between the bottom of the nutt and top of the flywheel, drop a socket over the nutt make sure the socket bottoms out on the nutt and does not touch the flywheel either . If the first hit doesn't loosen it, tighten the bolt more and give it one more hit. What are the steps to removing the flywheel? thread the "puller" into the flywheel/magneto and the "puller" will push the flywheel/magneto off as it bottoms on the crank. Feb 9, 2014. Go to Auto Zone or any auto parts store, purchase a puller for about a dozen bucks; purchase (3) bolts (M8 x 35mm x 1.25) that will fit into the three holes on the flywheel through the puller (turn them not more than seven turns/not full turns, just six turns of the wrist) crank the puller and vola, the flywheel will come off . Can someone tell me how to reinstall the flywheel? Nose bit is 31mm long & 5.5mm diameter. Had the same problem within the past month. First, you must re-install the crankshaft keyway. The images below explain that you need to magneto removal tool for the H2, but the correct protector you need to buy . Posts. Lightened flywheels are bad times lol. Don't lose the metal key that aligns the flywheel in the correct position. Remove the nut and lift off the flywheel. 1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250. the "puller" is just a longer bolt. Well-Known Member. Loosen the flywheel nut by using an impact wrench. now i remember i just took the lock bolt to the auto parts store and matched the threads. I didn't want to score the flywhee so I didn't use the chain wrench. When it wants to come off, it'll pop off. Motion Pro Magneto Flywheel Puller, 16mm x 1.5 Left-Hand - BikeBandit.com . i've taken off all the bolts I can see (allon, and the flywheel retaining nut). Do not get carried away and get it red hot or anything but get it hot enough you can't touch it. Ended up heating the shaft with a torch. 2.2.3. I used a big hydrolic press, support the case and just press the crank out, same thing on the way back in, just make sure it goes in straight and in all the way. Nose bit is 31mm long & 5.5mm diameter. The PTO hub and the flywheel with the magneto armature plate. Dont use a hammer could damage the crank. the lower hollow nut portion that threads into the crankcase is the correct thread for the ID thread of the fibre gear.You will have to cut the head bolt part off and thread the plain hole of the hollow nut- 7/16 anything will work. while prying hit the socket with big hammer, it should pop loose, never ever, never ever The PTO is threaded and the mag and flywheel are bolted on by a nut. once this is done take your wrench and break the bolt loose, do not remove it. with a mallet or lead hammer". Magneto puller can easily remove the deceleration plates and clutch plates without damaging your motorcycle. Re: Out of Tricks, very stuck flywheel. Loosen the flywheel nut by using an impact wrench. take the puller and thread your three screws into . There are two component parts to the ends of the crankshaft. It makes things go a lot smoother. at least from what i recall. The part is generally held in place as a press fit on the end of the crankshaft and has a woodruff key to stop it spinning. How do I stop my flywheel from . i usually put the nutt back on, but not screw it all the way down. Insert two bolts into the threaded holes on top of the flywheel. Tighten the center puller spindle dow as much as possible. a) remove the grease from the outer surfaces of the assembly units and parts with a rag soaked in gasoline and wipe it dry; b) rinse the candle in gasoline, dry it and wrap it in the candle hole in the cylinder. FLYPIG 24mm&27mm Flywheel Stator Magneto Puller Fit GY6 50 125 150cc ATC70 ATC90 ATC185 TRX 250R CR80 CR85 Yamaha YFS200 Blaster 200 Kawasaki Suzuki Flywheel Removal Stator Puller Repair . For the PTO hub, remove the 6 bolts, then use a puller. Feb 24, 2002. I removed the 17mm nut, then behind that is another threaded piece, that looks like you could get a socket on it, i have seen the special flywheel removal tool, does that work by pulling only, or is it loosening that threaded piece. A gear puller will work here if you can manage to hook it under the mag, otherwise, check for threaded holes in the mag that you can use to hook a puller to, sometimes a steering wheel puller is better than a standard gear puller. What I did was heat the end of the crankshaft to around 450 degrees, with oxy-acetylene and a rosebud, and quenched it with penetrating oil I had put in the freezer overnight. 5.0 out of 5 stars Great tool! Repeat the tightening and one hit until it pops. The optimal distance between the flywheel and the ignition coil is 0.2-0.4 mm for most chainsaws. If you treat it well, it will last 50 years or more. For the flywheel, remove the magneto, then use a puller on the flywheel. Loosen the flywheel nut by using an impact wrench. $12.85 $ 12. Flywheel magneto, used for atv dirt bike, pit bikes. Use penetrating oil to soak the impulse hub and a small puller to get it off. Have you removed the ratchet nut, it has standard right hand thread. Having to remove, and replace the bearing perhaps several times to get the shimming correct tells me that the services of a machine shop are need to properly make an accurate puller. After a short time, it should pop loose. A heat gun to warm the rotor hub and expand it might help if needed. 2) a puller to correctly remove flywheel. I learned this trick from watching a video an lawnmowers from the davidsfarm youtube channel. In the meantime, the puller is a powerful tool to lift and pull the flywheel. Posted November 18, 2009. If the flywheel wont budge after striking it a few times with a hammer, it's time to break out the big guns-the propane torch. Impact drivers work well for this, or you can use a penny into some meshing gears as well. You may also need a puller for the slip ring if it is stuck. Cta Tools Glow Plug Tip Puller Kit - Universal Many Applications. Flywheel magneto, good workmanship, can perfectly fit your model. A gear puller will work here if you can manage to hook it under the mag, otherwise, check for threaded holes in the mag that you can use to hook a puller to, sometimes a steering wheel puller is better than a standard gear puller. i had a two arm puller on it and it seemed like it was taking a little too much to . Pull a pretty good load on the screw, and get a torch and start heating it up. Hey guys, I need to remove the right side crank case, but don't have the puller, P/N 644-365. Aug 14, 2010. Replied by MarkT on topic AT-1 Armature Removal. Chinese ATV Flywheel Puller This specialty tool will make removal of those flywheels fast and easy! There have been a lot of older bike strip threads started recently so I thought I would post about the old skool armature removal. Make sure you use a flywheel/pulley puller. Once thats done take the cover off the points and remove the bolt in the center and take them out. The big bolt in the center of the puller pushes against the crankshaft extension and pops the assembly off. Apply gentle pressure on each screwdriver and get a mate to VERY lightly tap the flywheel with a hammer. How do I stop my flywheel from . 13,262. yes a puller is the best way:thumbsup: 1) a tool to hold flywheel while you loosen or tighten nut. How to Remove a Mercury Flywheel Unlatch the clips that are used to secure the cover and take the cover off the motor. For an alternative method, you can also use the rear axle bolt to fit into the larger thread instead of. You can: use a piston stop; do the rope trick Now you can install the magneto back onto the crank. Finally a good whack with the hammer on the bolt of the . put a bungie cord in one of the spark plug holes and turn the crank till the piston squeases on the cord. How to Remove a Mercury Flywheel. Nick. Will work on any atv with a starter clutch bolted to the back . go to an auto store get a universal flywheel puller (10- 15 bucks) take a large rachet w/ breaker bar if needed if you dont have air tools. Tap on the end of your puller a couple times, and it will pop off.. 01' Raptor 720, Stage 2, FCR'd 97' 250 Vitos Blaster 06' Rhino 450 94' Banshee T-5's, Vforce, ported, Cool Head, 2-1 06' Wolverine 450 - Stock! Helpful. The flywheel is on a tapered shaft so it will loosen upwards. Thanks to all who have offered help and advice, my " Heath Robinson" efforts at fabricating a puller without benefit of machine tools are suspect. Now turn the screw handle inward to contact the end of the crankshaft. pulley, then drawing off the flywheel with a puller. Oct 19, 2014. There are several ways to do this as well. This is a tutorial on how to easily remove a flywheel without damaging the flywhee. 6,380. get 2 flathead screwdrivers. When all else fails, heating the flywheel can often do the trick. 85. The flywheel can sometimes be stubborn, it takes technique not force to remove, Mercury Service Tools are nice but, there are work arounds, I assume the magneto is a Repco/Phelon Model 514 C (stamped on top of flywheel an magneto plate) Coils are hard to come by, but, OMC coils can be adapted. Not a good idea to apply heat (flame) to the flywheel. Thanks to all who have offered help and advice, my " Heath Robinson" efforts at fabricating a puller without benefit of machine tools are suspect. Reviewed in the United States on . #3. You may find techniques described on the internet for removing the inner race without any special tools. Orange Cycle Parts Magneto Flywheel Puller for Honda by Motion Pro 08-0026 Replaces # 07933-0010000 . Flywheel Stator Magneto Puller Removal Extractor Tool for Yamaha Pitbike 50cc-160cc. To remove the flywheel, there are several techniques. You have to order that separate and it is part number 0444-248. dont make the tool. The best way to remove a flywheel is to use a torque wrench set to 50 ft-lbs. I'm thinking you have the electric start model so puller is a 10x1.25 thread with an extended nose. remember you are hammering the crankshaft bearings) . You are not off track. 2.2.2. First, there is a nut on the flywheel which must be removed. The magneto removal set looks like part number 0444-254. Next, strike the center of the screw with the hammer. There might be a piece that fits onto the crankshaft extension so that the puller bolt does not bear directly against the crank extension. Flywheel Stator Magneto Puller Removal Extractor Tool for Yamaha Pitbike 50cc-160cc. Tighten the center screw REALLY tight then firmly strike the center of the puller screw with a medium size hammer. This video shows how to disassemble left crankcase cover and Flywheel or Magneto. Screw the puller collar fully into the flywheel. Remove the nut completely. Loosen the Flywheel nut till the end of the nut lines up with the end of the crank. Insert two bolts into the threaded holes on top of the flywheel. Line up the slot in the center of the magneto and push it onto the crank as far as possible. You thread the puller onto those threads, securing the body of the puller to the flywheel. #2. A simple hammer will do for impacting the end of the puller with one or 2 sharp raps (not a heavy blow, a sharp rap. Sometimes just have to let the oil soak a while and it will pop off with the puller. Replied by RT325 on topic 1975 DT125B Magneto Rotor Removal. The best way to remove a flywheel is to use a torque wrench set to 50 ft-lbs. The armature is a wire coil that forms part of the generator/starter. SabrToothSqrl. The Glow Plug Tip Puller Includes A Tap, Drill Bit, And Extractor Holders That Are Fitted To The Body Of The Original Plug And Slides In For The Perfect Setting. Get the bolt very tight, then hit the head once with a good sized hammer--3# or so. I just used the harbor freight one. ; 100% Brand New &High Quliaty ; M35x1.5mm Magneto Rotor Flywheel Puller.35mm diameter by1.5 right hand thread pitch ; Fitment: M35x1.5mm Magneto Rotor Flywheel Puller For Kawasaki KFX700 Brute Force 650 KVF650 ATV For Kawasaki Brute Force 750 & Teryx 750 2008 And Newer /Removes Kawasaki Rotor/Flywheel 21007-0111 And 21007-0158 Then take your hammer and hit the stem of the puller. Re: removing A10 magneto advice. 3) the correct size, 6 point, metric socket to use on nut, 25mm or whatever is correct. `10x1.25 pitch. Can you use heat to remove a flywheel? Magneto puller for repair and replacement. #2 The magnet rotor shaft is tapered with a woodruff key in it. When you remove the nut, you'll need to remove the flywheel with a gear puller, like a harmonic type puller. Using a good puller (instead of a cheap universal puller) was a must for me and even then I had to use of PB Blaster (liquid wrench) and light heat. Locate the flywheel cover in the motor and remove it to expose the flywheel. If your nut is on that tight, chances are that the flywheel is just as bad. Read more. On the counter balancer you need to look at the service manual its kinda tricky, theres dots on the balancer gear and the flywheel gear they . Locate the flywheel cover in the motor and remove it to expose the flywheel. Details: Total length: 87mm/3.42" Thread diameter: 27 mm/1.06" Color: As the picture shown Used to remove flywheel (magneto) from the crankshaft Features: This is a reversible flywheel removal tool for use with a number of different types of flywheel Remove Pitbike flywheels that cover the stator with ease and without damage with this purpose made tool Simply remove the centre nut on the . The most expensive item on your Husqvarna is the ignition. These will be to mount a puller to. Now, drill holes on metal pieces, make a thread of BSW in all holes by using of tape set, as shown in the image. Generally you need 4 items-. 2,519 Location: SLC you'll need a way to block the motor from spinning to rotate the bolt. Replied by RT325 on topic 1975 DT125B Magneto Rotor Removal. yes, a fly-wheel puller would be best unless some knows another method of removing it, the backing plate on theses engines will make it difficult to remove the fly-wheel and breaks easy, an idear is to modify the common pully puller used for automotive applications and lightly rapping the side of the fly-wheel to vibrate loose, Remove the nut and washer holding the flywheel on the crankshaft. I went looking for a pic of one, for guidance in improvisation, but no dice. For all Lucas magnetos, and for some other makes too, you will need a puller for removing the inner race of the bearing next to the slip ring. Only show this user. then whilst attempting to pull it off, tapping the end of the crankshaft. Have the puller bolts even, OR if shoulder type bolts, tightened down to their collar. Have any of you fellas conquered this mountain before? Flywheel magneto's puller is made of high quality metal material, durable and wearresistant. Put one either side of the flywheel and find something to lever off (i used the crankcase when i did it on my derbi). The Puller Kit Services Limited Clearances That Makes It Easier To Access Glow Plugs Closest To The Firewall. Armature removal. 10mm bit is 87mm long. in this video,see how i removed motorcycle flywheel without using a puller Just warm it around the center. In a pinch, you can also put rope into spark plug hole and turn the motor over into it. If the flywheel wont budge after striking it a few times with a hammer, it's time to break out the big guns-the propane torch. This comes with a crank protector, but it is not the right one for the H2 1000 motor. Tighten the handle down then strike the handle arm with a hammer for extra pressure on the screw. Worked very well did the job without being expensive! As mentioned , it really came off with a bang and came flying. 05 Rhino 660, 100.5 mm piston same compression, HotCam, Stock Muffler with Tip, 25" Grime Reapers, 14g rollers, UTVcrap Sheave, Orange Secondary Spring, UNI Filter w/ billet . Do I need a puller? There will usually be 3 small screw holes spaced evenly around the top of the flywheel. This will keep the flywheel from shooting off later. Then I threaded the puller onto the flywheel, tightened the bolt as tight as I felt I could get it without stripping threads and struck the bolt with a small sledge hammer. For motorcycle engine 100cc to 110c or similar to this type of engine.Subsc. If you've got no other choice buy to use that cheesy puller, put a good quality c-clamp (I prefer to use cant-twist type myself), on the outside of the arms that reach behind the flywheel and grab it. Remove the nut and washer holding the flywheel. some of the Yamaha's used a 1.5 pitch on the armature puller threads. 4.5 out of 5 stars 53. Flywheel Removal. During re-preservation, oil, gasoline and dirt are not allowed to enter the high-voltage ignition wire and fan. Locate the flywheel cover in the motor and remove it to expose the flywheel. Go down to the auto parts store, buy some breaking oil, soak the crank end where it comes through the flywheel. . Messages. Lift up on the flywheel and tap sharply down on the nut with a wood or plastic mallet (or use a block of wood and a hammer. Set it in the groove in the crank and lightly tap it into place making sure it is evenly tapped on both ends of the keyway. Thanks. 10mm bit is 87mm long. After cutting of all the required parts, make a slot on both the jaws and 2.5" metal piece (head of the bearing puller), as shown in the image. Unlatch the clips that are used to secure the cover and take the cover off the motor. So out came the compressor and impact wrench! I've got the flywheel puller and going through my repair manual I'm not seeing how to reinstall the flywheel. Jul 25, 2008. Sometimes you need to remove a chainsaw flywheel without the proper tools. I'm thinking you have the electric start model so puller is a 10x1.25 thread with an extended nose.