MaximusDecimus
New Member
I just pulled my flywheel on my '06 yesterday to inspect and repair the starter clutch. I used a harmonic balancer puller from Harbor Freight($13) and grade 8 bolts(M8x1.25 x90mm) and hardened washers from a hardware store. I had a hell of a time trying to get it off mainly because i couldn't lock the flywheel in place from moving! Bike was on its center stand, tried standing on the brake but it still turned when I would whack the 1/2" drive ratchet with a small sledge. Kept hitting it and then smacking the shaft as well but nothing. Was going to take the puller off and start over but when I smacked the ratchet to go counter clockwise and take pressure off the puller the whole flywheel popped off in my lap! ...I got lucky I guess. I didn't use a blow torch. I think just continuing to increase the pressure on the puller and then trying to work the flywheel off by hand by wiggling it back and forth in the end was what helped get it loose before it popped off. I also used a flat bar to stop the gear from moving at one point so I could get a few solid hits on the ratchet without the flywheel spinning. Is there a better method or tool for this?
My starter clutch bolts had loosened up, the starter clutch cover was marred and damaged from hitting the heads of the bolts but the rest of it was fine. Regardless, I had to order the whole assembly($115 OEM online), plus the three bolts, two crank cover gaskets, and a small copper washer for the drain bolt in the crank cover.
Will reassemble using red loctite and peening the new bolts as well. Just wanted to share my experience in case it's helpful or anyone has any comments on the flywheel turning while trying to tighten the puller.
My starter clutch bolts had loosened up, the starter clutch cover was marred and damaged from hitting the heads of the bolts but the rest of it was fine. Regardless, I had to order the whole assembly($115 OEM online), plus the three bolts, two crank cover gaskets, and a small copper washer for the drain bolt in the crank cover.
Will reassemble using red loctite and peening the new bolts as well. Just wanted to share my experience in case it's helpful or anyone has any comments on the flywheel turning while trying to tighten the puller.