81 KZ1000 Rotor removal, stuck tight!

I'm trying to remove the rotor assembly from my 81 KZ1000J model because it slips out of engagement when turning the bike over with the starter. I believe the pins are worn so I need to check it out. I don't have a rotor puller and tried using the rear axle which is the same right hand thread size but it wont budge. I'm thinking of ordering a puller for this bike but is there any other methods of removing this thing. Thanks.

The OEM Kawasaki puller is a double threaded end deal with a section in the middle to get a wrench on. [at least that's how it used to be] Get one, have it cut in half and then weld a nice size rod to form a T-Handle on the end of each threaded section. Use a hammer on the T-Handle to get the Rotor loose.

Somoetimes oil in the end of the crank can help to hydraulic the object off the crank. I used that trick on many a snowmobile clutch over the years...

Be careful you don't mess up the threads in the crank end!

Have a look at this recent post on the UK owners site!

www.z1ownersclub.co.uk/forum/viewtopic.php?t=756

I borrowed a Friends dent-puller from His Body-Shop...worked like a charm on the one I was having a fight with.

Thanks for all the help on this problem. I finally got it off with a rotor puller, a copper washer and a sextrillion pounds of torque. The three hex head screws where broken and stripped out. I was able to drill and tap new mounting holes and with three new bolts and some blue loctite I reassembled the assembly and it now works great. Thanks again.

Do you have any pics of your bike? I have the same bike, but I changed the handlebars. I have some pics, but its at night. Lemme show you.

Post edited by: kzwolfsr, at: 2007/01/26 21:51