Pulling off the generator to remove cranks

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busa1300
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Pulling off the generator to remove cranks

#1 Post by busa1300 » Sat Dec 08, 2018 1:53 pm

I have a proper puller for the flywheel, but I'm trying to do it without incident.
It will not pull off with a wrench, and am worried that if I use an impact I'll screw something up.
Do these pull off pretty hard?

Have to get cranks out for seals and possible bearings....sitting on the bench for six months hasn't seemed to do anything
I guess I need to get back at it....

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phildu31
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Re: Pulling off the generator to remove cranks

#2 Post by phildu31 » Sat Dec 08, 2018 2:58 pm

Do some heating of the rotor while in tension.

PaulGreen
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Re: Pulling off the generator to remove cranks

#3 Post by PaulGreen » Sat Dec 08, 2018 4:12 pm

Rubber mallet on the flywheel always worked for me.....

steveho
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Re: Pulling off the generator to remove cranks

#4 Post by steveho » Sat Dec 08, 2018 4:23 pm

Be careful of too much heat, as that can destroy the magnets.
A lot of force is often required.
I always use grade 12.9 bolts for the 3 off M8, as lower grades stretch.
Sometimes the torque that is required swells the end of the crank so that the generator nut won’t re-fit! That will require filing the OD to allow the nut to fit.
Just tighten the puller until the flywheel comes off the taper.
Good luck with the removal..... :grin:

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Speed Freak
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Re: Pulling off the generator to remove cranks

#5 Post by Speed Freak » Sat Dec 08, 2018 4:44 pm

Use a lot of grease on the thread of the puller. If the thread is dry you will only waste your force to overcome the friction instead of getting force into the flywheel.

I'm using a hydraulic flywheel remover as we had often issues to get the flywheel off on different engines.
Most of the time because they were tightened too much.
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

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tacky1
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Re: Pulling off the generator to remove cranks

#6 Post by tacky1 » Sat Dec 08, 2018 5:59 pm

I always tighten up the bolt on the pullers really well and give the end a good crack with a hammer, Thats the way I have been doing it since the dinosaurs...
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

theredbarron
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Re: Pulling off the generator to remove cranks

#7 Post by theredbarron » Sat Dec 08, 2018 6:23 pm

Tighten up the centre bolt tight tight and give a good whack.
If only there was more free time.

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Re: Pulling off the generator to remove cranks

#8 Post by silverstrom » Sat Dec 08, 2018 7:29 pm

With stubborn flywheels I tighten as much as I dare and walk away and leave it for a while. Come back and tighten again and wait a while. Repeat. It will come off eventually, often while you are in the waiting phase.

When installing any flywheel I always lap the flywheel to the crank before final installation.

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busa1300
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Re: Pulling off the generator to remove cranks

#9 Post by busa1300 » Sat Dec 08, 2018 10:15 pm

Got it...
Put some marvel mystery oil on the threads, got it pretty tight, then hit it with a hammer a few times.
Tightened it up just a little more and it popped right off with no harm to anything :smt023

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78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
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Kalim
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Re: Pulling off the generator to remove cranks

#10 Post by Kalim » Sun Dec 09, 2018 4:40 am

Well done :grin:

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busa1300
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Re: Pulling off the generator to remove cranks

#11 Post by busa1300 » Mon Dec 10, 2018 7:32 pm

Had to add.....those 3 bolts holding the inner generator cover on were a complete bitch to get out.
In order to get the cases split......The two inner bolts (under base gasket) at the lower edge of the lower cylinders has me worried as well... :smt017
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

ChequeredFlagRacing
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Re: Pulling off the generator to remove cranks

#12 Post by ChequeredFlagRacing » Sat May 23, 2020 3:23 am

busa1300 wrote: Sat Dec 08, 2018 1:53 pm I have a proper puller for the flywheel
Is that the Yambits puller or another brand?
https://yambits.co.uk/rd500-flywheel-puller-p-6247.html
Yamaha FS1E 1975
Yamaha RD200 1976
Yamaha RD400 1977
Yamaha AS3 125cc 1978
Yamaha AS1 125cc 1979
Honda CX500
Honda MT125cc 1980
Yamaha TZ125G 1981-82
Zeger TC500cc 1983-84
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Speed Freak
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Re: Pulling off the generator to remove cranks

#13 Post by Speed Freak » Sat May 23, 2020 6:08 am

Here a picture of my hydraulic tool.
In this case with a R1 RN04 flywheel which is a bit different as it only has a center thread.
This puller thread is a bitch, you will not get it off with a standard flywheel puller which is basically just a bolt.
Before you get it off 30% of the threads get damaged and then you are lost... Only chance to get it off then is to weld a nut to the flywheel.

In case of the 3 bolt removers just replace the center bolt by the hydraulic cylinder.

Image

The flywheel housing bolts have thread lock on them.
Warm it up before removing them.
And for the 2 bolts at the front you need a good tool as they have a small head and the hexagon is not really deep. Try to apply torque only and no other forces. I like to use a T-bar instead of a ratchet for such cases.

And if the hexagon is destroyed... A hammer and a Torx are your best friend.
Take the next size torx and hammer it into the hexagon as deep as you can. If you feel that it starts to turn in the hexagon take the next size torx.
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

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busa1300
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Re: Pulling off the generator to remove cranks

#14 Post by busa1300 » Sat May 23, 2020 8:32 am

ChequeredFlagRacing wrote: Sat May 23, 2020 3:23 am
busa1300 wrote: Sat Dec 08, 2018 1:53 pm I have a proper puller for the flywheel
Is that the Yambits puller or another brand?
https://yambits.co.uk/rd500-flywheel-puller-p-6247.html
The puller I used is older than the engine...It was my dads originally and he probably bought it some time in the 70's
It worked for the job I needed but not designed specifically for the job.
The two crankcase bolts....I ended up drilling the heads off. Then when case was split the rest of the bolt came out easy with a vise grip.
78 GS1000E
80 KD80
82 Katana
84 RZ350
84 RZV500R
86 GSXR1100
86 1100 sportster
88 FZR1000
89 RGV250 VJ21 SP
90 RGV250 VJ22 SP
91 TZR250 3XV2 SP
96 RGV250 VJ23 T SP
99 RS250
02 Hayabusa
16 KTM 390 Duke
17 KTM 1290 Superduke GT
21 Aprilia RSV4 1100

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wolfgangh
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Re: Pulling off the generator to remove cranks

#15 Post by wolfgangh » Sun Mar 27, 2022 12:37 pm

I am reading this thread now since I also currently try to remove the flywheel of my recently acquired 1GE. The engine was never open, so I guess the flywheel was mounted in the factory and never removed since. I am using the same flywheel puller that is shown above, so far with no luck. I would never hit the puller with a hammer since this force directly impacts the crank??? I will just leave under tension now for a while after I sprayed WD40 onto the joint, hoping it creeps in. I also only used 8.8 grade bolts which have stretched noticeably, so will need to get 12.9 grade bolts.

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