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Help Flywheel puller tool?

Discussion in 'Suzuki 250cc In-line 4's' started by SukiMan, Jan 21, 2018.

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  1. SukiMan

    SukiMan Member

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    In regards to fixing up my new Suzuki Across, I’ve recently just discovered on google that i need a special tool to remove the flywheel for when I get the new one on Monday.. now I’ve found one on eBay for $45 which I’m not buying because 1. It’s 45 bucks? 2. I’m probably never going to use the tool ever again/I’ll lose it in some dark abyss in my house, and 3. I’m still not back at work yet so I have no income at the moment due to my accident so I can’t buy anything anyway. Anyone know another way I can swap the flywheel without that special puller tool??


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    SukiMan, Jan 21, 2018
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  2. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    You should use the flywheel puller, maybe someone here is close by and could lend/rent you one?
     
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    my67xr, Jan 21, 2018
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  3. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I bought a decent one years ago, Motion Pro brand for $25 inc post off ebay US. Used it heaps of times and it still looks like new.
    Watch out for the cheap china ones, they can damage you crank and or flywheel.
    https://m.ebay.com.au/itm/MOTION-PR...283877&hash=item3f8b040311:g:Ng4AAOSwevdZ~fH2

    If you get stuck your local bike shop could help too, but it means taking the bike/s there and they might charge you $10-$20 to remove it/them if you need to remove 2 to get a good one.
     
    my67xr, Jan 21, 2018
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  4. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    How creative are you, and do you have an old bmx rear wheel/sprocket sitting around ?

    The bmx sprocket has the same size thread and pitch as the Suzuki Across flywheel use's, M30 x 1mm right hand

    11089.jpg



    You would need to weld a short length of thick wall tube to the sprocket hub, cut the teeth off if required.
    Next weld a high tensile fine thread nut to the inside of the tube (opposite end to the sprocket hub) to make it resemble something like this on the left below
    And finally get a high tensile bolt and grind a point into the tip (similar to the pic on the rights' centre bolt)

    s-l300.jpg mf9900056_mf9900056_01.jpg
     
    Last edited: Jan 21, 2018
    my67xr, Jan 21, 2018
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  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    See if the rear axle is the same size thread
     
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    Linkin, Jan 21, 2018
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  6. SukiMan

    SukiMan Member

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    A mate told me if I’m lucky I might be able to put a screwdriver between the flywheel and crank and just give the thread part a few taps with a hammer and it might pop off but if not I’ll need that tool. The only sprocket I have laying around is the old one from my Across from when I replaced with a new one :(


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    SukiMan, Jan 21, 2018
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  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Ummm I wouldnt give any threaded part a tap with a hammer... you will end up damaging the thread.
    Some flywheels fall off and others are on there forever...good luck with it...
     
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    Andych, Jan 21, 2018
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  8. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Screwdriver and hammer will not work. It might be fine on a lawn mower engine but not on something that requires an M30 thread for gripping. Buy, borrow or make the correct tool.
     
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    maelstrom, Jan 21, 2018
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  9. Bab

    Bab Well-Known Member

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    I've been in a similar situation and I was careful to buy a reasonable quality tool to do the job. Upon the completion of the job sold the tool at a discount and considered any loss as a necessary "rental" fee in order to get the job done without causing damage, loss of material, time, and further expenses.

    I buy middle of the line tooling, and with care and caution they last me as long as I'll ever need them, and those I want to eliminate I have been able to recoup a reasonable sum keeping losses to a tolerable amount.

    Occasionally I have loaned the tool when I couldn't convince someone to buy it, and in turn have called in favours which were a better return on my investment than the sale of the tool would have been. In my approach to survival, favours are a valued commodity. Like having a little cash squirreled away, you can always draw on it when it's needed.

    I have always stated "the day you make your money is the day you buy, and not the day you sell". Just another opinion, another way of looking at things...good luck with your puller which ever method you choose.
     
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    Bab, Jan 21, 2018
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  10. Joker

    Joker See "about me" for contact details. Contributing Member

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    Depending on the design, you may be able to do it with 2 flatheads and a mallet. I can do this on my FZR250's because the flywheel is attached to the crank facing "out" (ie the magnets face away from the engine) and the stator sits inside the cover. On my FZR400 it's the reverse of that, the stator is attached to the engine and the flywheel sits the opposite way round with the magnets on the inside. I had to borrow a puller for that, but it was basically just a giant threaded bolt I wound in until it popped off.

    If your across is like the 250, it's all about even pressure. carefully tap one screw driver behind the flywheel all the way down until it touches the crank. Then on the exact opposite side (ie 180 degrees) do the same with another flat head. You'll get to a point where your tapping it with a mallet and you'll hear a "ping" and it will come straight off. Be very careful doing it though.

    Photo below doesn't show it attached but shows you what I did (the below was a bandit flywheel, could do it on those too).

    2014-02-22 16.53.30.jpg
     
    Joker, Jan 21, 2018
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  11. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I can't believe you are an Engineer and do it this way ?
     
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    my67xr, Jan 21, 2018
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  12. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    This is an Across flywheel, look's very similar to the FZR250 flywheel's with the male thread on the boss/hub
    It look's like it has 3 tapped hole's around where the rivet's are, you might be able to use a cheap steering wheel puller and 3x bolt's
    Just make sure you loosen the flywheel retainer bolt a few turn's before trying to get the flywheel off so the puller s' centre bolt doesn't damage the threads in the crank

    img_20171202_094256.jpg

    s-l500.jpg

    [​IMG]
     

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    my67xr, Jan 21, 2018
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  13. SukiMan

    SukiMan Member

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    I’ve literally got no money I can’t buy any special tools or anything so it sucks but my Across flywheel is the same as the Bandit and looks almost identical to the FZR250 so the screwdrivers may work, this is basically what my flywheel looks like (this is a pic of the flywheel from my accident bike, not from the bike that is getting a replacement flywheel) I will be testing the screwdriver theory with this bike because the flywheel is already totally ****** on it so if it works without damaging anything, I will do it on the new Across f60a99f6702d539fcc5cb60fd39e4727.jpg


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    SukiMan, Jan 21, 2018
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  14. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    IF you must do it that way, then use something flat like tyre levers so that you don't damage the alloy cases where the gasket sits.
     
    Murdo, Jan 22, 2018
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  15. Joker

    Joker See "about me" for contact details. Contributing Member

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    This method might be higher risk than using a puller perhaps, but it works on exactly the same principle. If you're not comfortable with the risk yourself then don't attempt it. That doesn't mean it doesn't work or other people haven't done/can't do it. Yes you have to be careful but yes it works.
     
    Joker, Jan 22, 2018
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  16. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Did the lecturer's at your Uni teach you how to do that sort of thing when you studied Engineering?
    Or is that a you just part of being a 'creative' engineer
    I am not having a go at you, just trying to understand thing's a bit better

    So same principle's,
    Bolt fitted onto thread's on flywheel hub push's against loose flywheel retainer bolt so pressure on hub/crank is central and even, v's 2x screwdriver's pushing against 2 side's of the flywheel while being pushed into the alloy engine case each side of the flywheel to try to lever it out isn't the same principle is it ?
    I think levering a flywheel off could easily break or damage the epoxy bond of the magnet's to the flywheel as there'd have to be some flex involved ?
    I have seen a couple of flywheel's that have been levered off and caused the outer ring to be warped compared to the hub it's riveted too.
    And i wouldn't think tapping the screwdriver's in each side with a mallet would do the crank bearing's etc any favour's either

    I guess you could also use a slide hammer or 2 to take the flywheel off as well then,
    it might be a higher risk than using a puller, yes you'd have to be carefull, and yes it'd work

    Sound's a bit like compressing piston ring's with a hose clamp v's using a piston ring compressor
     
    my67xr, Jan 22, 2018
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  17. Joker

    Joker See "about me" for contact details. Contributing Member

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    Dude, keep on topic. It works. Move on. If you want to debate about methodologies by PM then send me one. Just bear in mind what you wrote reads as if you're trying to insult my intelligence, so be prepared for the counter.
     
    Joker, Jan 23, 2018
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  18. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Personally I think @my67xr was on topic... mostly trying to help the OP avoid doing any more damage by NOT removing the flywheel properly.
    My motto is if you cannot do it properly... DONT, especially if you are not well versed in the art of Bush Mechanics... which is what the screwdriver method is.. . We have all done things the wrong way at times.. or used fencing wire to hold something together as there just wasnt any other way... but that really isnt the case here.
    There is too much leeway for damaging mating surfaces etc all for the sake of a $25 puller from Supercheap.
    46 years experience in the engineering trade starting with Aircraft Maintenance Engineering all the way up to designing 2500HP cooling water pumps for a Gold mine in Indonesia tell me that doing it the wrong way will lead to tears... especially for the inexperienced.
    Just my 2 cents worth.. and you can take from it whatever you want... but personally... I would beg borrow or steal enough to buy a cheap puller from Supercheap... or even better...
    https://www.ebay.com.au/itm/FLYWHEE...hash=item1ea8f7e7ad:m:mIXHwXjOntjlZdfVIlrzFbQ
     
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    Andych, Jan 23, 2018
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