Can't remove rotor - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 4 (permalink) Old 07-04-2016, 04:02 PM Thread Starter
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Can't remove rotor

Well my son and I are replacing his broken shifter rod this weekend. Turns out some PO has had it apart a little because at some time the basket mod has been done. So far everything was going great, until we tried to remove the rotor/flywheel. I have the long 18m bolt from the Harbor Freight gear puller set that is the right thread. But how tight is that sucker (rotor) on? I have not gotten it to budge even a smidgen. I can order the specific puller bolt through Cycle Gear and have it by Thursday but I really donít see how that bolt will make any difference. Tried soaking in a bolt hole full of PB Blaster overnight but so far no go. Any hints or other tricks or do I just keep at it with the impact wrench? I even thought about using a little heat on the hub with some aluminum backed starter insulation (the kind I use to protect my Rancheroís starter from the headerís heat) between the hub and the outer rim of the rotor but I know heat can ruin the magnet. Any tips or experiences?

Also for the record, I defy anyone from replacing the broken rod without splitting the case. No way to remove the broken one using only needle nose pliers. I can see the broken shaft but it is on with LockTite or something similar.

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post #2 of 4 (permalink) Old 07-04-2016, 05:47 PM
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An air impact gun should knock right off, didn't take much on mine.

Cordless/electric impact, I'm not sure.

Should only take a nudge, since the shaft is tapered.

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post #3 of 4 (permalink) Old 07-04-2016, 07:56 PM
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Mine popped off easily with the MotionPro bolt?

1986 Kawasaki Vulcan 750
NGK Iridium Plugs #7803/DPR7EIX-9
Duralast Gold ETX15 AGM Battery
Coastered & Shaved
Metzeler ME880 [110/90-19, 170/80-15]
Balance Dampers Replaced
Tuxedo Mod
Rebuilt Forks w/ Progressive Springs
V&H Cruzers Grill Cover
Meanstreak Seat
Emgo 23-92411 Handlebars

1990 Kawasaki Vulcan 750

1998 Honda VFR800 FI

2014 Honda VFR800F

1989 Pontiac Firebird Formula 350
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post #4 of 4 (permalink) Old 07-04-2016, 08:14 PM Thread Starter
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That was the bolt I was going to order. Then a new step backwards.

I was using an old 3 bolt puller bolt from Harbor Freight. However it was the kind that had a pivot built on it. The pivot had been lost long ago so I just ground it down to a nub and screwed it in. While I was a H.F. today (getting a free LED light and some brushes) I saw a different puller. One in a nice box with the exact size bolt right on the cover. Brought it home and looked at it to see how it was nice and flat on the end. Went to try it and surprise, no go. Not even close

Doing some thread comparisons I discovered that the threads in the rotor are now NF not metric. I guess when the PO tore it down for whatever purposes, in addition to doing the basket mod he re-tapped the threads in the rotor to NF. Kind of like using the Cummins bolt but backwards. Now it is back to the drawing board. hopefully I can fit a shaft into the crankcase for the bolt I have to but against and pop the rotor off. Otherwise we will be getting a new rotor and getting the old one off however we can. I do not think there is enough material left to tap the threads back to metric.

At least the basket mod is done.

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