TOPIC:

larrycavan wrote:

9am53 wrote:

larrycavan wrote:

9am53 wrote:

Yeah, my patience usually wears people down, but this motor is tougher than most people! lol I am getting sick of looking at the motor in the same state it was in weeks ago, but the day I get to split the cases will be that much sweeter! Thankfully this is not my main ride, so I am not in a rush. Last years project is running fantastic, I did an 800 km ride in very cold temperatures last weekend and she was a dream, so obviously I don't suck that much!

You first and biggest mistake without having a proper tool was in pulling the top end off before you pulled the rotor.

I get frustrated with people that try to go to step 15 before they do the first 14 .... so don't get mad at me Adam.... I'll get on your case from time to time but dam it boy.....you need that...suck it up and be a man...

I had to remove the top end to get the motor downstairs, my staiwell is really old and narrow and steep, and I couldn't get it down there safely withought removing some weight/size. Not to mention that I have never heard or been told that you remove the rotor first, remember, this is my first time doing this? I don't know what step 14 or 15 are, if somebody here doesn't tell me it and the manual doesn't tell me it, then I don't know it. I can take people making fun of it taking 3 weeks to get a rotor off, I would too, but I don't get pro's geting mad at a first timer when he is having a particularly tough time with something.

Adam,

You were given every conceivable method of pulling that thing.

I'm not saying that the rotor isn't stuck. It may well be. The point is, if it was going to come off with and axle and a ball bearing it would be off by now.

At one point you said you bought some harbor freight universal puller. What did that cost?

You could have purchased the correct tool for probably less than $20 and bought yourself an electric impact gun for not a lot of money. Combined they would = ROTOR OFF...

The electric impact would always be useful. The rotor puller is handy to have.

The puller I showed you has the same shape as the one in the photo but it's much stronger and will pop the rotor without shocking the magnets.

You want to work on bikes then buy some tools and make your life a lot easier. That's what the Pros do.

JMO

It's not like I have been banging on my axle for the last few weeks, I tried it, and since it didn't work I have been waiting for the bolt so I can use my impact wrench to try another method.

I did get a cheapo gear puller, but returned it after you mentioned not to pull on the starter gear. I got an air impact gun, and a compressor with some other useful tools (air ratchet, hammer and die grinder) I could have ordered the tool from Z1 and used the ball bearing method, but I erroneously thought I could get it faster and cheaper in town. Fastenal screwed me around for a week and a half so I am getting a bolt this evening (essentially the same as the Z1E tool) and have a nut that I will use in lieu of a ball bearing. I would have tried making a T handle like you showed but I don't have a welder or a spare axle.

I will get it off, and we can all laugh that my rotor pulling escapade is longer than many entire build threads! lol

Best to heat it up and use a good penetrant on it now, and maybe pop off the pistons and run a rod through the piston rod ends, to prevent the crank from turning when you're ready.

You can assist the impact tightening the bolt by twisting the socket with your hand while running the gun.

Rotors, magnetos, and such can be very strange in how they seem to be on there super strong, but with the correct tools (impact gun, bolt - dont need ball bearing, I've never used one after heat and penetrant), the darn things just pop off like they where never really on there that hard to begin with. You'll see...

Do it, just DO IT.

I don't think the proper tool and an impact wrench is the absolute solution in every case. My rotor would not come off either and after trying everything known to man I used my impact wrench on the flywheel puller I got from Z1E. Guess what happened? The puller broke off right in the flywheel and still didn't come off! I could show you pictures of what I had to do to get that rotor off but your stomachs couldn't handle it!

I used heat from a small propane torch and it didn't help. I think the proper puller with some REAL (red hot) heat would work, but not everyone has an acetylene torch. Beating extra hard to loosen a stuck rotor has to take it's toll on the crank so what do you do? You have the tool in the rotor, it's very tight, and you hit the puller with a hammer and it still doesn't come off. It's not always as easy as you all make it sound.

I had an 81 KZ1000 with the same issue. Nothing worked, even the correct tool, combined with the biggest impact wrench the dealer had, and two hours of labor. It never budged. Good luck.

I'd just cut it off. Cut vertically across the hole. The problem is, getting a cut off tool or dremel in far enough to get it into the tapered part.

9am53 wrote:

larrycavan wrote:

9am53 wrote:

larrycavan wrote:

9am53 wrote:

Yeah, my patience usually wears people down, but this motor is tougher than most people! lol I am getting sick of looking at the motor in the same state it was in weeks ago, but the day I get to split the cases will be that much sweeter! Thankfully this is not my main ride, so I am not in a rush. Last years project is running fantastic, I did an 800 km ride in very cold temperatures last weekend and she was a dream, so obviously I don't suck that much!

You first and biggest mistake without having a proper tool was in pulling the top end off before you pulled the rotor.

I get frustrated with people that try to go to step 15 before they do the first 14 .... so don't get mad at me Adam.... I'll get on your case from time to time but dam it boy.....you need that...suck it up and be a man...

I had to remove the top end to get the motor downstairs, my staiwell is really old and narrow and steep, and I couldn't get it down there safely withought removing some weight/size. Not to mention that I have never heard or been told that you remove the rotor first, remember, this is my first time doing this? I don't know what step 14 or 15 are, if somebody here doesn't tell me it and the manual doesn't tell me it, then I don't know it. I can take people making fun of it taking 3 weeks to get a rotor off, I would too, but I don't get pro's geting mad at a first timer when he is having a particularly tough time with something.

Adam,

You were given every conceivable method of pulling that thing.

I'm not saying that the rotor isn't stuck. It may well be. The point is, if it was going to come off with and axle and a ball bearing it would be off by now.

At one point you said you bought some harbor freight universal puller. What did that cost?

You could have purchased the correct tool for probably less than $20 and bought yourself an electric impact gun for not a lot of money. Combined they would = ROTOR OFF...

The electric impact would always be useful. The rotor puller is handy to have.

The puller I showed you has the same shape as the one in the photo but it's much stronger and will pop the rotor without shocking the magnets.

You want to work on bikes then buy some tools and make your life a lot easier. That's what the Pros do.

JMO

It's not like I have been banging on my axle for the last few weeks, I tried it, and since it didn't work I have been waiting for the bolt so I can use my impact wrench to try another method.

I did get a cheapo gear puller, but returned it after you mentioned not to pull on the starter gear. I got an air impact gun, and a compressor with some other useful tools (air ratchet, hammer and die grinder) I could have ordered the tool from Z1 and used the ball bearing method, but I erroneously thought I could get it faster and cheaper in town. Fastenal screwed me around for a week and a half so I am getting a bolt this evening (essentially the same as the Z1E tool) and have a nut that I will use in lieu of a ball bearing. I would have tried making a T handle like you showed but I don't have a welder or a spare axle.

I will get it off, and we can all laugh that my rotor pulling escapade is longer than many entire build threads! lol

Good for you on buying some tools

Someone told me that's Nads conducting

youtube.com/watch?v=76RrdwElnTU

could somebody post up "The Anvil Chorus"?bj

hocbj23 wrote:

could somebody post up "The Anvil Chorus"?bj

ROTOR OFF !!

Absolute proof of the "Don't force it, use a larger hammer " theory

youtube.com/watch?v=zxY2wky6oZ4&feature=fvst

Actually I think we're right about here at this point

youtube.com/watch?v=mYRnnHOHrEo&feature=fvst

So, I tried...here is a short vid of me trying. Sorry about the ending

s289.photobucket.com/albums/ll231/9am53/...uckinggayness001.mp4

put the bolt back in there and split the cases already,joes getting ahead of ya!

9am53 wrote:

...here is a short vid of me trying. Sorry about the ending....

What PSI to air gun?

Good Fortune!

PLUMMEN wrote:

put the bolt back in there and split the cases already,joes getting ahead of ya!

fuck man, just use a 3/8" drive and a breaker bar. you seen my hand didnt ya? sounded like dinner was ready at the end...