starter clutch

[archangelof2003]

ok.  So I have read all the threads I can find on this topic and hate to even ask but you guys have been a great (and fast) help in the past so here goes:

I'm taking the flywheel off my bike to replace the starter clutch.  I have the main crank bolt out and have a puller on it but it just does NOT want to come off.  I cranked on it till it would not crank any more then used the delicate art of harmonics (pounded the end of my puller with a 4lb hammer) and still nothing.  Am I missing something?  Are they all this tight?  I even went to my local dealer to look at their 25 year old manual and it told me nothing special....HELP!

[Lucky]

tighten, pound, tighten, pound, tighten, pound...pop!

[kwells]

...duck!....

[inanecathode]

Make sure your puller is pressing on the crank not the flywheel.

[Tiger]

:) Tighten, pound, carefully, on the flywheel, tighten, pound on the flywheel, etc, and somewhere along the line...pop. Make sure that...1- you have something on the floor, (I used an old bath towel), to catch the flywheel/rollers/end caps/springs...2- During this procedure of...tighten/pound...stand/squat/kneel to the side of and not dead center of the flywheel :o It weights in at a few pounds and literally flies off of the shaft...you do not want to have your body part's in the way ::) ;D :D :D :D

                              8).......TIGER....... 8)

[Tanno]

I'm also looking forward to this today. I have my newly rewound stator and going to get this knocked out also. Does anyone know where I can get a 46mm crow's foot today? Sears maybe?

[Night Vision]

nope, not sears around here.... you can go to Ace and find a Plumbers Crescent wrench for around $10. Finish tightening with a sharp punch on the corners of the nut... I also bent over both tabs, not just the one that'll land on a flat, but the other one also, bent it right around a corner of the nut.

with out a 46mm deep socket, you can't torque it to spec... just do the best you can do because it'll be better than it was....

[archangelof2003]

WOW....you guys were serious about that.  It would not come off till  I had the puller as tight as I could humanly get it and pounding on the end with a sledgehammer....If you only knew how nervous I was!  It did come off, I did need a new one, and everything is working good now.  So now I'm back to carb tuning.  Thanks for your help.

[h2olawyer]

When I did mine, I debated on buying a high quality puller or a cheapie from Harbor Freight.  Went for the cheapie since pounding hard on the end of a tool normally destroys the warranty.  Better to be out $15 or $20 than $50.  However, I ended up using a pneumatic impact wrench and the flywheel just slid off nice & easy.  No parts flying or anything like that.  Highly recommended method for this job.

H₂O

[inanecathode]

Aye yeah, an impact is probably the right tool. Were i to do my starter clutch i'd definitely use an impact.

[archangelof2003]

uh..yeah....Mine must have been the factory one cause It would not budge even with 110psi on the impact on the end of my average price puller.  F*&^er was stuck!  I got it though.  Nothing a bigger hammer won't cure!

[h2olawyer]

I know mine was the factory install (bought the bike with 6 miles on the odometer).  It's always had indoor storage.  Other environmental factors may have led to yours sticking harder.  I normally run my impact @ 110 psi as well.  I still subscribe to the bigger hammer theory on occasion as well.   ;D

H₂O