View Full Version : How do I remove flywheel, 2007 Hyosung GT250?
hsrb87
25th September 2011, 12:27
The reason for this is about 1/4 of the teeth have stripped off the starter cog. Any tips would be appreciated. I have mechanical experience but mostly on larger machinery :yes:
FJRider
25th September 2011, 13:38
Buy a workshop manual for it ... they explain how ...
marty
25th September 2011, 14:17
remember:
1. - if you can't fix it with a hammer, screwdriver and pair of pliers it's probably an electrical fault, and
2. - if the starter dog is stripped, why do you need to remove the flywheel?
hsrb87
25th September 2011, 16:14
sorry not flywheel but magneto rotor similar to page 13 & 14 in this link:
http://razza.org/service/GT250%20Service%20Manual/GT20Chapter203_part1.pdf
Any ideas how to stop it turning as I don't want to remove the engine from the bike, or take the heads off. I have tried putting it in gear but that didn't work.
FJRider
25th September 2011, 16:19
sorry not flywheel but magneto rotor similar to page 13 & 14 in this link:
http://razza.org/service/GT250%20Service%20Manual/GT20Chapter203_part1.pdf
Any ideas how to stop it turning as I don't want to remove the engine from the bike, or take the heads off. I have tried putting it in gear but that didn't work.
In gear with foot on BACK brake ... ???
Katman
25th September 2011, 16:33
Any ideas how to stop it turning as I don't want to remove the engine from the bike, or take the heads off. I have tried putting it in gear but that didn't work.
I'm always dubious about offering mechanical advice to the clearly mechanically clueless. (Sorry but your suggestion that removing the engine or taking the heads off would make loosening the flywheel nut easier confirms it).
But.....
A carefully held spanner on the nut with a sharp rap from a hammer will often loosen the nut.
Trouble is, removing the nut is the easy part.
Getting the flywheel off the crankshaft without a suitable puller is another story.
hsrb87
25th September 2011, 16:42
I'm always dubious about offering mechanical advice to the clearly mechanically clueless. (Sorry but your suggestion that removing the engine or taking the heads off would make loosening the flywheel nut easier confirms it).
But.....
A carefully held spanner on the nut with a sharp rap from a hammer will often loosen the nut.
Trouble is, removing the nut is the easy part.
Getting the flywheel off the crankshaft without a suitable puller is another story.
I only mentioned Removing engine /heads etc as that is what online workshop manual has done with a special crank holding tool (see link above). my real question is how best to lock it up so it wont turn without damaging anything else.
FJRider
25th September 2011, 16:47
I only mentioned Removing engine /heads etc as that is what online workshop manual has done with a special crank holding tool (see link above). my real question is how best to lock it up so it wont turn without damaging anything else.
Remove KEY from ignition and KEEP ... replace EVERYTHING else ... :innocent:
Problem solved .... :yes:
It IS a Hyo ... :facepalm:
hsrb87
25th September 2011, 16:59
Remove KEY from ignition and KEEP ... replace EVERYTHING else ... :innocent:
Problem solved .... :yes:
It IS a Hyo ... :facepalm:
Its almost getting that way. I have only had it three months and have already done fuel pump diaphragm (i think it was, done under warranty) then dash played up (seemed to right itself, may have got wet) now this.
Seriously thinking giving up all together.
FJRider
25th September 2011, 17:06
Its almost getting that way. I have only had it three months and have already done fuel pump diaphragm (i think it was, done under warranty) then dash played up (seemed to right itself, may have got wet) now this.
Seriously thinking giving up all together.
Serious advice ... YAMAHA ... :yes:
hsrb87
25th September 2011, 19:04
Serious advice ... YAMAHA ... :yes:
yes I know you are right now but have two mates with hyosungs who have no complaints so i think I just got a lemmon :facepalm:
FJRider
25th September 2011, 19:08
... but have two mates with hyosungs who have no complaints so i think I just got a lemmon :facepalm:
Give them time ... they too will see ... :innocent:
hsrb87
25th September 2011, 19:13
Give them time ... they too will see ... :innocent:
well one has since sold his so only one to go..... lol
Im just very glad i didnt decide to sell my car when i got mine
DrunkenMistake
25th September 2011, 19:56
WOAH WOAH WOAH
WHAT ARE YOU DOING MAN?
BIKES DONT HAVE FLY WHEELS!
:innocent::innocent::innocent:
Lets see who gets this one..
tigertim20
25th September 2011, 19:59
WOAH WOAH WOAH
WHAT ARE YOU DOING MAN?
BIKES DONT HAVE FLY WHEELS!
:innocent::innocent::innocent:
Lets see who gets this one..
well SOMEONE's gotta remove them!:facepalm:
hsrb87
25th September 2011, 20:03
WOAH WOAH WOAH
WHAT ARE YOU DOING MAN?
BIKES DONT HAVE FLY WHEELS!
:innocent::innocent::innocent:
Lets see who gets this one..
Sorry wrong choice of words, like i said am more used to larger machinery.
DrunkenMistake
25th September 2011, 20:14
Sorry wrong choice of words, like i said am more used to larger machinery.
Didnt notice your relativity new,
was a bit of a piss take,
Ignore it haha,
get yourself a PDF workshop manual, or join up at www.korider.com they are pretty much the Hyosung forum, they will sort you out.:yes:
hsrb87
25th September 2011, 20:26
Didnt notice your relativity new,
was a bit of a piss take,
Ignore it haha,
get yourself a PDF workshop manual, or join up at www.korider.com they are pretty much the Hyosung forum, they will sort you out.:yes:
all good, thanks for the advice
Rhys
25th September 2011, 21:35
try to beg borrow or steel an air gun (sometimes called a rattle gun) that will undo the nut but as has been stated earlier you will need a set of pullers, super cheap auto or repco will have a cheap set or you can hire them from hire pool etc
good luck :scooter:
SS90
25th September 2011, 23:47
Didnt notice your relativity new,
was a bit of a piss take,
Ignore it haha,
get yourself a PDF workshop manual, or join up at www.korider.com they are pretty much the Hyosung forum, they will sort you out.:yes:
I wondered if someone would pick up on " Afterbirth of a Monster" reference..... HSRB87.... A flywheel is anything that stores kinetic energy..... And is critical in the balance of an engine (well one that is rideable below full noise anyway).... A magneto is also flywheel in the case of a motorcycle.
You where correct calling it a flywheel.
hsrb87
26th September 2011, 20:03
I wondered if someone would pick up on " Afterbirth of a Monster" reference..... HSRB87.... A flywheel is anything that stores kinetic energy..... And is critical in the balance of an engine (well one that is rideable below full noise anyway).... A magneto is also flywheel in the case of a motorcycle.
You where correct calling it a flywheel.
haha sometimes i surprise myself! it seemed logical at the time to call it that. hopefuly il get my work tool box home tomorrow and have another go.
i have acess to pullers, so hopefully that part is sorted.
then i'll have to get a replacement cog. will try dealer or is there anywhere else i could try?????
bucketracer
2nd October 2011, 20:32
That workshop manual was all about a full engine strip.
my real question is how best to lock it up so it wont turn without damaging anything else.
You don't need to lock it up.
A carefully held spanner on the nut with a sharp rap from a hammer will often loosen the nut.
Trouble is, removing the nut is the easy part.
Getting the flywheel off the crankshaft without a suitable puller is another story.
If the carefully held spanner doesn't work out, the local garage (or if you have to, a tire shop) will get the nut off with a rattle gun no problems.
A rattle gun is good at getting stuff undone but can over tighten a nut doing it up again so you will need to be carful about that.
And its best to do it out of gear, as you don't want to damage anything else in the engine/gearbox. The rattle gun works against the inertia of the rotor and crank and jars the nut loose like the sharp rap on a carefully held spanner can, but its much easier to use a rattle gun if the nut is really tight.
When I had to take a Suzuki RGV rotor off recently I got an after market puller for it from the local bike shop, about $30 from memory. I just had to know the thread diameter and pitch of the rotor boss.
Metric thread pitch is the distance from the top of one thread to the next, if you don't have a thread gauge an easy way to work it out is to use a small rule and count the number of threads in a center meter (10mm) then divide by ten, you will probably get a number like 1 - 1.25 - 1.50 or 1.75
The rattle gun and special puller worked for me and made the job easy, with no damage.
get yourself a PDF workshop manual, or join up at www.korider.com (http://www.korider.com/) they are pretty much the Hyosung forum, they will sort you out.:yes:
Korider looks a likely bet for more good info ....... there may be someone there who has done this job on the same bike as yours before.
The net is a great place, a search may turn up more useful info, lots of good stuff out there.
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