Suzuki 2 Strokes

I am sure that this has been asked and answered many times, but I can't find it; and I can't seem to find it in the workshop manual either.

How do you get it off the shaft?

I just used a standard all-purpose three legged puller which are available from lots of places. Don't thread in the bolts too far though into the face of the rotor, as you risk damaging the insulation on the coils mounted underneath. I ended up replacing my coils anyway as the fibre spacers had disintegrated and so the coils were loose on the cores with the lighting and generating coils, but you may be luckier and may be able to keep the originals.

OK, thanks. However, I looked at available 'gear pullers' and they had claws that hook under the 'gear' and there is no space between the rotor and the housing for that.

I see the three available screw holes... do you need a particular 'gear puller' that fits these?

Roger

Look for a steering wheel puller They can usually be found for around $15 or so - if you are in the USA then try Ace Hardware or Harbor Freight, in Canada try Canadian Tire or Princess Auto.

Hi Roger.....it's quite easy to make a device for removing the rotor. Find a flat piece of steel 3mm thick or maybe a little more, and drill 3 holes to line up with the 3 on the unit. Gently and evenly bolt it to the bike, (the alternator cover bolts do the job from memory)....it will pull against the end of the crank and pop the rotor off. Works every time.

my dad came up with a very simple tool to do this. i guess it works like the steering wheel puller above.
take a scrap piece of flat steel and drill three holes in it in the exact pattern of the threaded holes in the flywheel. place on top of the big nut in the middle of the flywheel and screw in three bolts until they just start to tighten.
i certainly hope this makes sense. bit of a laguage barrier here as i am danish.
now tighten the bolts equally half a turn at the time. this will press the steel plate aganst the nut and pull off the fly wheel.
i will try to get a photo later.

http://pinkpossum.com/GT750/Crank%20pullers.htm" onclick="window.open(this.href);return false;

Click on the thumbnail pictures for the larger image

tz375 wrote:http://pinkpossum.com/GT750/Crank%20pullers.htm" onclick="window.open(this.href);return false;

Click on the thumbnail pictures for the larger image

Thanks TZ... a useful link. Here is the Pink Possum's instructions in a printable form if anyone else wants them.

Roger

One slowly evolving GT500A

oldjapanesebikes wrote:Look for a steering wheel puller They can usually be found for around $15 or so - if you are in the USA then try Ace Hardware or Harbor Freight, in Canada try Canadian Tire or Princess Auto.

Well I found a tool exactly the same as this one... however bolts that fit the flywheel have head that are too small for the slots in the arms of the puller. So I put washers on the bolts and tightened it up....

The washers just folded in half and pulled through the slots... how tight on is this flywheel!!??

Roger

Roger....the steering wheel puller is doing the same job as my bit of metal with 3 holes suggested in my earlier post.....get some good tension on the bolts, then give the unit a good tap with a small hammer. We have had some sticky ones in the past, but never one we didn't get off using this method.
Good luck.

+1 to Titan Performance comment - I admit I've only had to pull 2 GT500 rotors, but both were tighter than my Grandad with his spare change As suggested, a sharp 'rap' seems to to the trick.

Thanks guys... I will go and get some more suitable washers to pack out the screw heads and try again...

oldjapanesebikes wrote:+1 to Titan Performance comment - I admit I've only had to pull 2 GT500 rotors, but both were tighter than my Grandad with his spare change As suggested, a sharp 'rap' seems to to the trick.

Tight! Bl**dy h*ll it was tight alright... but with a loud bang it finally let go!

Am using a 3-bolt puller as recommended.
Where do you recommend I should strike with that good tap?

jabcb wrote:Am using a 3-bolt puller as recommended.
Where do you recommend I should strike with that good tap?

When the puller is tight, hit the centre bolt of the puller sharply with a hammer.