SuzukiSavage.com - how do we remove the flywheel ?

suzi-q Junior Member Offline SuzukiSavage.com Rocks! Posts: 87	Re: how do we remove the flywheel ? Reply #15 - 12/27/18 at 08:40:06 hi. I like the looks of your seat. what tank do you have on yours? thanks
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: how do we remove the flywheel ? Reply #16 - 12/27/18 at 08:45:23 suzi-q wrote on 12/27/18 at 08:40:06: hi. I like the looks of your seat. what tank do you have on yours? thanks 1972 Suzuki GT380/550.....claims to be 4 gallons.
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suzi-q Junior Member Offline SuzukiSavage.com Rocks! Posts: 87	Re: how do we remove the flywheel ? Reply #17 - 12/27/18 at 19:44:52 hi. I got the 17mm hex head bolt out. now the next nut is a 36mm. I saw someone say a 46mm. is this the same nut.? I have a 36mm socket that fits. I see a woodruff key in there. dose this have to come out first? if so, how do we get this out? thanks all
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Fast 650 Senior Member Offline SuzukiSavage.com Rocks! Posts: 410 Valrico, FL Gender:	Re: how do we remove the flywheel ? Reply #18 - 12/28/18 at 00:50:22 This is the 46mm nut (red arrow) that you have to remove.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: how do we remove the flywheel ? Reply #19 - 12/28/18 at 03:10:35 Yep, that is the next nut to be removed. You can take it off easy with an impact wrench - but torquing it back in place requires you to hold the flywheel stationary.....that is what the tool does that bolts into the threaded holes in the flywheel.
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suzi-q Junior Member Offline SuzukiSavage.com Rocks! Posts: 87	Re: how do we remove the flywheel ? Reply #20 - 12/28/18 at 08:01:32 I have been calling the rotor the flywheel. duh. that 36mm nut has a woodruff key in there. should this come out first? thanks
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: how do we remove the flywheel ? Reply #21 - 12/28/18 at 09:02:52 The only thing under the flywheel nut is a spring washer......nothing else needs to come off to loosen the nut. The flywheel has splines holding it from turning on the crank.
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Fast 650

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Re: how do we remove the flywheel ?
Reply #22 - 12/28/18 at 09:05:01

Yep, the woodruff key will prevent the nut and flywheel from coming off so the key has to come out first. And it is a really tight fit in the crank. I had to use a hammer and a drive punch to get mine out. Be careful not to damage the slot in the crank when you are hammering the key out though. Woodruff keys are cheap if you beat them up too bad to use again, crankshafts are expensive.

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suzi-q Junior Member Offline SuzukiSavage.com Rocks! Posts: 87	Re: how do we remove the flywheel ? Reply #23 - 12/28/18 at 11:12:05 so do I drive the woodruff key inward? can't see it coming out. and then remove the 34mm nut? thsnks
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Fast 650

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Re: how do we remove the flywheel ?
Reply #24 - 12/28/18 at 13:37:33

You loosen the 17mm bolt a few turns then screw the puller onto the rotor. As you tighten the long bolt in the puller it presses against that 17mm bolt. Run the puller bolt down tight and give it a smack with a hammer and it should pop the rotor free then. Now you can remove the puller from the rotor, finish removing the 17mm bolt, and slide the rotor off.

Now you have access to the woodruff key to drive it out of the slot.
You will understand how this works immediately when you see the puller (that I am assuming you don't have yet).

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suzi-q

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Re: how do we remove the flywheel ?
Reply #25 - 12/28/18 at 16:13:12

hi. I could not see how this tool works. after searching it seems that the 36mm hex head nut with what looks like 50mm threads under it, dose not unscrew from the rotor as i was thinking. but it is used to screw the tool on. is this correct? then the smaller bolt on the tool does the pulling. is this tool a 50mm x1.5 R H female thread? if so my searches show the price for this tool is all over the place. I found this one. pit posse pp3271 50mm x 1.5 R H female thread. is this the size I need? thanks

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Fast 650

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Re: how do we remove the flywheel ?
Reply #26 - 12/28/18 at 18:50:36

That is right, and that is the correct part number for the puller too. The next hard part is finding a 46mm socket that is deep enough so you can get the flywheel nut off. Some people have found them with no trouble, but I couldn't find one anywhere when I needed one. I finally cut a short one in half and welded a piece of tubing between the two halves to make it longer.

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: how do we remove the flywheel ? Reply #27 - 12/28/18 at 19:46:10 OK....now I see why I was confused about this thread. It was fast 650 that posted the photo of the engine with the rotor and woodruff key already removed. Suzi-Q has not gotten this far yet. Suzi-Q.....do you have a Clymer manual?
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suzi-q Junior Member Offline SuzukiSavage.com Rocks! Posts: 87	Re: how do we remove the flywheel ? Reply #28 - 12/29/18 at 11:15:48 hi dave. I do have a Clymer manual. I have the tool on the way. what brand o f deep socket and just how deep do I need to get. I love tools. love this bike.
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Armen Serious Thumper Offline Half-Witted Wrench-Jockey from Jersey Posts: 1454	Re: how do we remove the flywheel ? Reply #29 - 12/29/18 at 17:38:41 I found a deep socket and squared up the face on the lathe to get a better purchase on the rather shallow nut.
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