Trouble removing flywheel? Look here - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 14 (permalink) Old 07-29-2017, 08:03 AM Thread Starter
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Trouble removing flywheel? Look here

Hey guys so currently I am splitting the case on my 750 to fix a broken shift linkage. So far ita going smoothly and I will have the case actually split within an hour. During this process so far I found out something that you guys may appreciate.

Not sure how often we actually have to remove the flywheel/alternator wheel from the crankcase but if you guys need to remove it, you may be aware that it requires a speciap kawasaki tool to actually grab the flywheel and remove it without damaging it.

Though some of you may be aware that you can use a 18mmx1.5mm bolt as well and it works the same.

After calling around everywhere to every motorcycle shop in the area, i quickly found out that the flywheel puller tool has gone extinct to all dealers and I couldnt find it online either. Same goes for the 18mmx1.5mm bolt, its a super uncommon bolt that would need to be special ordered online and I didnt want to have to have something shipped to me just to remmove the flywheel.

But I found a solution, since the flywheel has a bolt in it that is connected to the sprocket behind it, I figured I could use a 3 jaw puller that I rented from advanced auto could probably get the sucker out. AND IT DID! used the 3 jaw puller fastened it to the lips of the flywheel and tightened it very slowly, after about a minute of tightening, the fly wheel popped right off without a scratch! So if gou guys need to remove the flywheel, try this method. It could save you alot of frustration!
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post #2 of 14 (permalink) Old 07-29-2017, 08:24 AM
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3 jaw pullers can break the flywheel. its not solid steel. it has magnets in it, and if they get cracked (which may not be visible) its shot.

alternative to the flywheel puller tool (the bolt), is a bolt for the upper chain tensioner.. just above the acct (or mcct if converted), on outside of the head. I (and others) have used it with success. its the right size thread,, just a hair short. you can use a small socket inside it (its hollow) to give it that little extra length (it dont need much). pops right off using it.

the thing is, ANY pulling/pushing force on the outside of the flywheel, can break the magnets. thats why the flywheel is threaded in the fashion it is.

*note: some 3 jaw pullers, and other pullers, use a M18x1.5 thread on the main shaft/bolt. that will work just fine by itself (JUST the bolt, none of the other stuff)

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post #3 of 14 (permalink) Old 07-29-2017, 09:28 AM
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I can get a whole box of the right bolts locally for $20. Ebay also has the puller bolts all the time, about $12.

The same bolt is used to pull the flywheel on a 1987 Honda Foreman TRX350D, so it's probably used on other machines too.

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post #4 of 14 (permalink) Old 07-29-2017, 10:33 AM
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probably used on a lot of japanese designed engines

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post #5 of 14 (permalink) Old 07-29-2017, 12:05 PM
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Quote:
Originally Posted by michiganteddybear View Post
probably used on a lot of japanese designed engines
Looks like a lot of Kawi and Honda. Ninja, Mojave, TRX atv, CB750-1000 ... just using the bolt size on ebay. No doubt there's a lot more than that.

And I probably already had a drawer full on other pullers. d'oh Didn't even think to check.

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post #6 of 14 (permalink) Old 08-02-2017, 05:47 PM
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Quote:
Originally Posted by Spockster View Post

The same bolt is used to pull the flywheel on a 1987 Honda Foreman TRX350D, so it's probably used on other machines too.
Trx300fw as well.
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1981 KZ750
1988 Vulcan VN750 (red)
2005 Vulcan VN750 (silver)
(2) 1994 Vulcan VN750 (red)

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post #7 of 14 (permalink) Old 08-02-2017, 06:17 PM
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Trx300fw as well.
Is that the same TRX with the 18w LED headlights, posted in the headlight thread? Looks like a bright azz headlight in those other pics.

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post #8 of 14 (permalink) Old 08-02-2017, 06:23 PM
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Yep. Cree 18w floods.
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post #9 of 14 (permalink) Old 08-02-2017, 07:37 PM
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Yep. Cree 18w floods.
Will be looking for some. They look perfect for a Foreman.

Now I get it, saw the square lights in the other thread, but focused on the red atv with round lights in this thread.

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post #10 of 14 (permalink) Old 08-02-2017, 08:35 PM
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All the same lens housing in the older models. Swapped the fourtrax lens into the recon when i upgraded cause the recons were shabby. Identical lens and housing from 85 to 2003 on all models with square headlights. No modification needed on the cree, direct bolt on.

I was wrong on price, they were only $18.95 each not $24.
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