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Thread: How do I remove flywheel, 2007 Hyosung GT250?

  1. #1
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    25th September 2011 - 12:15
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    How do I remove flywheel, 2007 Hyosung GT250?

    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

  2. #2
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    Buy a workshop manual for it ... they explain how ...
    When life throws you a curve ... Lean into it ...

  3. #3
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    22nd August 2003 - 22:33
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    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?

  4. #4
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    25th September 2011 - 12:15
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    sorry not flywheel but magneto rotor similar to page 13 & 14 in this link:

    http://razza.org/service/GT250%20Ser...r203_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.

  5. #5
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    Quote Originally Posted by hsrb87 View Post
    sorry not flywheel but magneto rotor similar to page 13 & 14 in this link:

    http://razza.org/service/GT250%20Ser...r203_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 ... ???
    When life throws you a curve ... Lean into it ...

  6. #6
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    Quote Originally Posted by hsrb87 View Post
    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.

  7. #7
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    Quote Originally Posted by Katman View Post
    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.

  8. #8
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    Quote Originally Posted by hsrb87 View Post
    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 ...

    Problem solved ....

    It IS a Hyo ...
    When life throws you a curve ... Lean into it ...

  9. #9
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    Quote Originally Posted by FJRider View Post
    Remove KEY from ignition and KEEP ... replace EVERYTHING else ...

    Problem solved ....

    It IS a Hyo ...

    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.

  10. #10
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    Quote Originally Posted by hsrb87 View Post
    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 ...
    When life throws you a curve ... Lean into it ...

  11. #11
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    Quote Originally Posted by FJRider View Post
    Serious advice ... YAMAHA ...
    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

  12. #12
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    Quote Originally Posted by hsrb87 View Post
    ... but have two mates with hyosungs who have no complaints so i think I just got a lemmon
    Give them time ... they too will see ...
    When life throws you a curve ... Lean into it ...

  13. #13
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    Quote Originally Posted by FJRider View Post
    Give them time ... they too will see ...
    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

  14. #14
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    WOAH WOAH WOAH
    WHAT ARE YOU DOING MAN?
    BIKES DONT HAVE FLY WHEELS!






    Lets see who gets this one..

  15. #15
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    Quote Originally Posted by DrunkenMistake View Post
    WOAH WOAH WOAH
    WHAT ARE YOU DOING MAN?
    BIKES DONT HAVE FLY WHEELS!






    Lets see who gets this one..
    well SOMEONE's gotta remove them!

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