Jump to content

  • Do you own an ATV or UTV? Join our Forum!

    Join QUADCRAZY ATV Forum today for FREE! We keep these forums clean and user friendly. All first posters will have to wait to have their content reviewed and approved. Once your first post is approved, you will no longer need to got through an approval process. To gain immediate approval and a NO ADS experience, consider subsribing to our Premium Membership.

Stuck flywheel


Recommended Posts

I use a puller and give them a tap with a hammer.. but if you aren't used to doing things like that it's probably best to buy a custom puller for that job.. They can be had for as little as twenty bucks.. and last forever.. Google flywheel puller and your bike brand.

Are you sure you need the flywheel off ?

Link to comment
Share on other sites

Looks like it, I found a green/red wire from the stator going behind the flywheel cover and it is severed,  not enough behind the cover to splice.   I'll try to post a pic 

It's a project my neighbor gave me,  I replaced the ignition coils,  cdi,  regulator to finally get the plugs to spark. but they only sparked for a second when cranking then quit so I'm thinking of replacing the stator when I saw the g/red wire.

Link to comment
Share on other sites

Put your puller on, wind it up fairly tight.. Then use an eight ounce engineers hammer(engineers hammer !), and give the bolt on the puller a sharp hit. It would pay to be holding the flywheel away from the engine as much as possible.  Not a really hard hit, just swing the hammer a short way, but fast, and let it bounce back away from the puller. Depending on the end of of the shaft, and the end of your puller, it might be best to have the nut on the crank bolt..

That works on most bits of machinery, but some of those cheap import jobs these days are made really really badly, and it is possible that something could get bust.. I'd imagine there are fine threads on or in the outer end of that flywheel. If you measure the diameter of the threads, and using metric bolts to check what pitch the threads are, you can probably buy a puller made for a jap bike. The thread diameter has to be measured to what the outside diameter of the threads are. They will be metric, probably in whole mm. If you have a vernier caliper it will be easy. If not, you might be able to use something like a pair of scissors as a gauge, then apply it to a ruler.

Edited by Mech
Link to comment
Share on other sites

Did you get what I meant about the hammer hit ?

If we want to move a tight shaft in a hole, we use a big hammer and hit hard, and don't let it bounce.. That has a lot of drive to it... and could bend your crank..  Just a short sharp hit, that bounces the hammer back away.. That's what you want.

Link to comment
Share on other sites

Good. Try and hold the flywheel firmly away from the engine when you hit it, even the tiny amount of play in the bearings will help prevent the bearings getting impacted when you hit the puller..

And that's a big puller, it can likely pull with ten tons or more. Don't over tighten it or it may bend that flywheel. The shockwave from the hammer is what's going to loosen the flywheel on the tapered shaft..

Edited by Mech
Link to comment
Share on other sites

Ok, those copper coils will be for battery charging, the two covered ones will be for the cdi charging, and that black box is the trigger coil..  Betcha..

The battery coils will have a low impedence/resistance reading, the two will have higher resistance, and the trigger.. it will have a higher resistance still,..

Pretty sure those cut wires will be neutral light..

Link to comment
Share on other sites

I don't suppose you have a wiring diagram..  It's just possible those wires might go to a neutral switch, that effects the ignition..  Some small two-strokes start up with rev limiters for safety reasons, till they are in gear. If it has a centrifugal clutch, that would be a possibility..

Link to comment
Share on other sites

I checked resistance of the 3 yellow stator wires,  1-2, 2-3, 1-3 , all show about the same ohms 

Assuming the loose green/red wire (the pic of it on my knee)  is a neutral switch,  how do I get to where it plugs in?  Maybe pull covers off the other side?

Link to comment
Share on other sites

But now diagram huh...

Well check for continuity/resistance from the cdi, down to the various windings in the stator. Each wire at the cdi will either have a there and a return wire from the stator, or just one that goes to earth. Just check there is continuity with your ohm meter to start, don't worry about the exact readings..

Then try the same process to trace the wires to the key switch and kill switch..  Try and make a wiring diagram.. Just draw where each wire goes as you check it's continuity. Some wires might go to the switches and to the cdi or stator.. Draw switches as boxes till we figure whether they are meant to be open or closed for run. Draw the stator real basic and don't worry about what set of wires is inside, just where the wires run on the bike.

We can probably make a wiring diagram..  Or a whole new loom if need be.

To test those broken wires on the motor, put it in gear and use the ohm gauge on the bits of wire you can see to check if they are earthed or connected or open circuit. Then put it in neutral and repeat the process.

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.
Note: Your post will require moderator approval before it will be visible.

Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

  • Similar Topics

    • By Atvguy0901
      Thank for the add on quad crazy. I am new here and need some help with my atv. It’s a older Yamaha Timberwolf 250 that I purchased second hand from an person. I got it home ans started to look into it. He stated it needed a cdi box so I ordered one for it and a battery as well also a key switch cause it did not come with one. I put all the parts on it and when I hit the start button it just clicks and noting else. Thank you any help is appreciated. 
    • By Mikey69
      Heres my story. Kinda long. I guess I was a late bloomer when it comes to quads. I had never ridden a quad in my life. Rode Dirt Bikes as a kid growing up. Back in Oct of '06 I found a Mustang on craigslist. Took it for a test drive one morning before work. Fast car. 351 Cleveland. I had planned on meeting the guy again after work. For some strange reason thats still to this day beyond me, I stopped in Hillsboro MotoSports on the way home from work. I had 6 Grand on me. There was a left over '05 sitting by the front door. It was on sale for $4999. It was $5499 OTD. I didnt even look at anything else. I knew nothing about quads accept I thought it really looked coool and I had the money in my pocket to buy it. I was sitting on it when the salesman walked up and asked... "Can I help you?" Without hestitation I pulled 60 Ben Franklins outta my front pocket and said "I want this Quad. Load it up in my truck." It was just about dark by the time I drove away from the shop. BTW, I didnt bother to ask my ol lady if I could buy it. LOL. Anyway, I took it by the house and showed her. She was kinda stunned but not mad. We drove over to a friend of mines house and unloaded it. I took it to the field across the street from his house. HOLY CHIT!!!!! I was surprised by the power. I had it for about 2 weeks and took it to Sand Lake. I was there a few hours and rolled it on a banked turn at the top of the bowl right before you get to the one-ways. When it rolled, I flew off and landed on my belly. The quad came bouncing and landed on my back. For a month I couldnt even walk. I was scared of it. I considered trading it for a 250EX. Went back to the shop. The salesman said..."Dude!!! You dont want a 250EX!!! Trust me. Just get used to it" I still wasnt convinced. I put it on craigslist for $4000. Calls were coming in. I had a guy that wanted to come look at it that evening. I decided to take it for one last ride at Browns Camp before I sold it. I was still afraid of it. After about 5 minutes I started feeling comfortable on it again. I decided right then, I loved my Honda 450 and would learn how to ride it instead of selling it. That was late Nov of '06. Work was slow for a Painter in Oregon. My new job everyday? Going to Browns Camp and ridding my Quad. I bought my Girl Friend an '02 Blaster. I rode my 450 for 4-6 hours almost every single day for 3 months. And yes, I know my way around Browns Camp pretty well. LOL. In March I bought her an '06 TRX250EX (Thank God I didnt trade my 450 for one of those) LOL Since then, I have become totally addicted to quads. I love them. Couldnt imagine not owning at least one quad. Luckily I have two. My "07 was $6500 OTD in July of '07. Bought it for my Girlfriend. Traded in her 250 EX. A month later we broke up. So, I wound up with two Honda 450's.
    • By Malcolmconyers
      After riding around neighborhood with kids gear indicator just shows dashes along with eps not working at all after cycling on when key is turned to on position
    • By germs
      I have a 2008 250 bayou I got cheap. Real cheap. The guy said I just needed to remove and replace a couple stator rotor bolts that broke off when he was fixing it, not the case. I think he put it back together wrong and drove it. I'm new to this so not sure what all the parts are called or really even how or what has to be fixed. Any help would be greatly appreciated.

    • DIY like a pro! Shop from over 1,000,000 Repair Manuals at eManualOnline.com! As low as $14.99 per manual. Shop now.
    • By mhcchamp2023
      Hi All,
      When I get my foot off the throttle the engine brakes but the sound is not as it use to be = very loud.
      The noise began (not sure it is relevant) after I have replace the 2 u-joints on the rear shaft (between the transmission the the rear differential)  and engine oil change.
      Important to say that when accelerating all sound and works perfect, the noise is only when I get my foot of the throttle.
      Any idea what might be the cause?
      Thank you.
  • Gallery Images

  • Recently Browsing   0 members

    • No registered users viewing this page.

  • Create New...