flywheel removal

[lele]

hello..

I need to remove the flywheel-generator rotor of my fjr because I think the starter clutch got some problem.

Service manual say to use a sheave holder with yamaha PN 90890-01701 only to loose the bolt and then use a puller to remove the flywheel.so my question is: does anyone have ever did this before? my problem is to find a flywheel holder here in Italy, and I notice 2 holes on the DENSO flywheel, are they made for a special tool able to block it?the bolt is tighten to 130N and is very hard to loose anyway..

thanks and sorry for my bad english

ciao

 

[Luis]

Lele,

There is a nice "how-to" section here: https://www.fjrforum.com/forum//index.php?showtopic=126839

Luis

 

[lele]

I thank you but my problem is on the starter clutch, not on the main clutch

when I start the bike, few instant before ignite it made a strange noise on the generator side, so i think the starter clutch got some wear...to remove this small clutch I need to remeove the flywheel before!

Lele,

There is a nice "how-to" section here: https://www.fjrforum.com/forum//index.php?showtopic=126839

Luis

 

[ionbeam]

The bolt in the end of the rotor comes right out. The rotor is press fit onto a cone shape shaft and it is extremely difficult to get it to pop off. One Forum member tried making a home made puller and bent up a couple of different pullers he made without getting the rotor off. Eventually he did make a puller that got the rotor off but it was very hard. This is one case where you may need to buy or borrow a puller or have a dealer pull the rotor for you.

 

[lele]

Buy a puller is not a problem, the problem is the bolt in the end of the rotor as you call it.. because is near impossible hold the flywheel and loose a bolt tight at 130 N/m

The bolt in the end of the rotor comes right out. The rotor is press fit onto a cone shape shaft and it is extremely difficult to get it to pop off. One Forum member tried making a home made puller and bent up a couple of different pullers he made without getting the rotor off. Eventually he did make a puller that got the rotor off but it was very hard. This is one case where you may need to buy or borrow a puller or have a dealer pull the rotor for you.

 

[fudgejerkin1188]

Put the bike in gear and get some one to hold the rear wheel (or apply the rear brake) as you crank the nut

 

[Donal]

130 NM is about 96 ft/lbs. If you get a 3 ft bar that's only 32 lbs on the end of the bar. As for holding the rotor, I would put the bike in fifth gear and have someone else apply weight to the foot brake. The important thing is not to apply any impacts with this method as there is a risk of damaging gears etc.

Don

 

[HaulinAshe]

I can normally loosen the rotor bolt using a good air impact without putting anything in gear and risking damage. I use the in-gear hand method and torque wrench on the re-assembly.

A purchased puller is a must in my book. Too much at risk.