How do I hold the flywheel still? - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 26 (permalink) Old 1-23-2020, 1:19 PM Thread Starter
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How do I hold the flywheel still?

Trying to pull the flywheel so I can replace a broken starter clutch sprocket but how do I keep the engine from turning so I can get torque on the bolt? I've seen the 'lower a rope into your spark plug well' method but I'm wondering if there's a better/easier way. Thanks!
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post #2 of 26 (permalink) Old 1-23-2020, 1:30 PM
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strap wrench

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post #3 of 26 (permalink) Old 1-23-2020, 1:38 PM
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Or put it in 1st and have someone else lock the rear brake.
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post #4 of 26 (permalink) Old 1-23-2020, 3:31 PM Thread Starter
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strap wrench
Picked up a strap wrench at Home Depot. Thanks again @ducatiman!
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post #5 of 26 (permalink) Old 1-23-2020, 3:33 PM Thread Starter
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Or put it in 1st and have someone else lock the rear brake.
Going with the strap wrench but thanks for the suggestion!
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post #6 of 26 (permalink) Old 1-23-2020, 4:02 PM
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I use a bit of metal 4" long just prop it between the hole in the rim and the casing. pick a strong spot so as not to break the housing.

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post #7 of 26 (permalink) Old 1-23-2020, 5:51 PM
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The strap wrench will work easiest if you position it so that you can use the bike frame to brace the handle of the wrench.

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post #8 of 26 (permalink) Old 1-23-2020, 10:34 PM
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don't forget that bolt is left hand thread. I used fog's method. but if you want to use the strap method why buy one you can make one easily piece of !/2in flat wood cut two slots in it one 2in from end another 4in from end get an old belt. slide belt through end slot right up to the buckle. then put belt around flywheel sliding the belt through the other hole from the other side pull it tight hold rest of belt onto wood with one hand while undoing bolt with other. simple. you can also us it on the oil filter costs nothing.

Last edited by yorkie; 1-23-2020 at 10:53 PM.
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post #9 of 26 (permalink) Old 1-24-2020, 1:21 AM Thread Starter
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don't forget that bolt is left hand thread. I used fog's method. but if you want to use the strap method why buy one you can make one easily piece of !/2in flat wood cut two slots in it one 2in from end another 4in from end get an old belt. slide belt through end slot right up to the buckle. then put belt around flywheel sliding the belt through the other hole from the other side pull it tight hold rest of belt onto wood with one hand while undoing bolt with other. simple. you can also us it on the oil filter costs nothing.
wish I saw this earlier! Good thing it was only $10
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post #10 of 26 (permalink) Old 1-24-2020, 8:10 AM Thread Starter
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[QUOTE=Kevinl314;926747]
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Originally Posted by yorkie View Post
don't forget that bolt is left hand thread. I used fog's method. but if you want to use the strap method why buy one you can make one easily piece of !/2in flat wood cut two slots in it one 2in from end another 4in from end get an old belt. slide belt through end slot right up to the buckle. then put belt around flywheel sliding the belt through the other hole from the other side pull it tight hold rest of belt onto wood with one hand while undoing bolt with other. simple. you can also us it on the oil filter costs nothing.
Also I know the flywheel puller is reverse threaded, but so is the orange bolt holding the flywheel in the first place? If so then what is the difference between that and the puller?

Last edited by Kevinl314; 1-24-2020 at 8:21 AM.
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post #11 of 26 (permalink) Old 1-24-2020, 3:36 PM
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[quote=Kevinl314;926753]
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Also I know the flywheel puller is reverse threaded, but so is the orange bolt holding the flywheel in the first place? If so then what is the difference between that and the puller?
The flywheel bolt is reverse (left hand) thread, the flywheel PULLER is NOT, it is standard (right hand) thread.

FYI, a good impact gun does the trick too. I've been using an air impact on these flywheel bolts for years and it removes the need to keep the flywheel from rotating. However, when using the flywheel puller, always do it by hand.

When you finally get around to reinstalling the flywheel, the hardest part will be ensuring the spring loaded pucks in the flywheel don't fall out. The tiny springs wear out and if the pucks keep wanting to fall out, stretch the springs out to provide more pressure to the pucks. Then, when installing the flywheel, you'll have to rotate it a small amount but quickly to get the pucks to roll in far enough to clear the starter clutch sprocket. Don't forget to line up the slot in the flywheel with the woodruff key in the crank. It doesn't have to be lined up perfectly before getting the flywheel starter clutch pucks up and over the clutch sprocket, but it will help to have it close. Once the pucks are over the sprocket, rotate the flywheel until it is lined up with the woodruff key.

It sounds a bit complicated, but it's really not unless the puck springs aren't providing adequate pressure to keep the pucks from falling out.

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post #12 of 26 (permalink) Old 1-24-2020, 5:49 PM Thread Starter
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[QUOTE=Saabnut;926763]
Quote:
Originally Posted by Kevinl314 View Post
Quote:
Originally Posted by Kevinl314 View Post

Also I know the flywheel puller is reverse threaded, but so is the orange bolt holding the flywheel in the first place? If so then what is the difference between that and the puller?
The flywheel bolt is reverse (left hand) thread, the flywheel PULLER is NOT, it is standard (right hand) thread.

FYI, a good impact gun does the trick too. I've been using an air impact on these flywheel bolts for years and it removes the need to keep the flywheel from rotating. However, when using the flywheel puller, always do it by hand.

When you finally get around to reinstalling the flywheel, the hardest part will be ensuring the spring loaded pucks in the flywheel don't fall out. The tiny springs wear out and if the pucks keep wanting to fall out, stretch the springs out to provide more pressure to the pucks. Then, when installing the flywheel, you'll have to rotate it a small amount but quickly to get the pucks to roll in far enough to clear the starter clutch sprocket. Don't forget to line up the slot in the flywheel with the woodruff key in the crank. It doesn't have to be lined up perfectly before getting the flywheel starter clutch pucks up and over the clutch sprocket, but it will help to have it close. Once the pucks are over the sprocket, rotate the flywheel until it is lined up with the woodruff key.

It sounds a bit complicated, but it's really not unless the puck springs aren't providing adequate pressure to keep the pucks from falling out.
Thanks! I’ll let you guys know how it goes
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post #13 of 26 (permalink) Old 1-24-2020, 7:20 PM
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What pucks? there isn't any springs or pucks in the flywheel

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post #14 of 26 (permalink) Old 1-24-2020, 8:38 PM
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What pucks? there isn't any springs or pucks in the flywheel

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think he is referring to the starter clutch. I always assemble the clutch and sprocket before fitting then it goes on in one piece ok so you have to slide the starter out to get the chain and sprocket on but that's no biggie
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post #15 of 26 (permalink) Old 1-24-2020, 9:17 PM
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Correct, I am referring to the starter clutch assembly on the back side of the flywheel. While it technically is separate of the flywheel, the 3 allen bolts holding the whole assembly to the flywheel are only accessible when off the crank, so I always refer to the starter clutch as if it is a part of the flywheel.

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post #16 of 26 (permalink) Old 1-27-2020, 12:38 PM Thread Starter
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Okay, So I managed to get the orange bolt out that was holding the flywheel but how much force does it actually require to pull the flywheel? Because it’s not budging. I was careful to make sure the bolt was threaded properly and just wanted to make sure I won’t break anything by giving it some force

Last edited by Kevinl314; 1-27-2020 at 12:46 PM.
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post #17 of 26 (permalink) Old 1-27-2020, 1:28 PM
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strike it gently with a heavy hammer, like bump with a 4 pound sledge
That is the end of the tightened puller


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post #18 of 26 (permalink) Old 1-30-2020, 1:02 PM Thread Starter
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Starter gear is replaced, flywheel is back on, all was well until the head broke off my left hand threaded Flywheel bolt under about 100lb of torque. Anybody know where I can get a new one? Do places like Lowe’s or Home Depot carry reverse threaded bolts?
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post #19 of 26 (permalink) Old 1-30-2020, 1:25 PM
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all I've got available is a Gen 1 service manual which calls for 51 lb/ft.

Near 100? How did you come upon that spec?

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post #20 of 26 (permalink) Old 1-30-2020, 1:32 PM
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another win for the torque wrench

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post #21 of 26 (permalink) Old 1-30-2020, 3:04 PM Thread Starter
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Found one on an OEM parts website thanks everyone, for some reason I thought it was supposed to be torqued to like 120lb. Whoops!

Last edited by Kevinl314; 1-30-2020 at 9:33 PM.
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post #22 of 26 (permalink) Old 1-30-2020, 4:47 PM
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another win for the torque wrench

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You can't blame it on the torque wrench, if he's going to purposely torque it to 100 ft.lbs. (or maybe higher, that is just where it snapped).

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post #23 of 26 (permalink) Old 1-31-2020, 12:58 PM
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I have never used a torque wrench when installing the flywheel bolt and never had one back out. The left handed nature of the threading prevents them from loosening over time. Make it good and tight and call it a day.
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post #24 of 26 (permalink) Old 1-31-2020, 1:20 PM
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I have never used a torque wrench when installing the flywheel bolt and never had one back out. The left handed nature of the threading prevents them from loosening over time. Make it good and tight and call it a day.
yeah totally agree I have done the flywheel removal and refitting about 6 times now and never use a torque wrench tighten it up until it bites then one more flat that's it, it will never back out being left hand thread and as long as it is tight enough to hold the flywheel on the taper your good.
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post #25 of 26 (permalink) Old 1-31-2020, 2:21 PM
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Fact is if you have properly cleaned the taper (internal & external) then installed it properly . after the bolt was tightened once ,you could remove it and throw it away.
Ask any one who has tried to remove the wheel without a proper puller.

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