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Old 04-23-2006, 12:39 AM
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Default flywheel change

How hard is it to change a flywheel? I am going to a lightweight and want change it myself. Is there any tips to this or will the new one come with instructions. Thanks
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Old 04-23-2006, 01:07 AM
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I had mine replaced by a shop, but Nichols gives good instructions. Here is the link, http://www.nicholsmfg.com/flywheel-inst.html , just click on your bike description. I hope this helps...
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Old 04-24-2006, 06:26 AM
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nichols directions are pretty good. i used it along with my shop manual to figure out the terminology. i remember there is one torque setting that is wrong. the NM number is right, but the ft lb number is wrong. i (i'm sure like everyone else) meant to call/email nichols and tell them of the typo, but never did (i busted a 3/8" allen socket - craftsman - thankfully ). so, double check all the conversions before you get started. you will like the mod - i guarantee it.
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Old 04-24-2006, 05:05 PM
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It isn't all that difficult, and the Nichols instructions are quite good. Allow yourself some time. There are two tools you need that aren't always in the standard kit. An impact wrench (to remove the nut) and a 1/2" torque wrench, my 3/8" torque didn't go high enoungh. Also, be careful as the inside edge of the flywheel is razor sharp and it's easy enough to slice a finger.
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Old 04-24-2006, 05:21 PM
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Thanks for the pointers.


Jacob
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Old 04-24-2006, 08:54 PM
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You don't need an impact wrench. Put a penny in the gears and just use your normal breaker bar. Put the penny back in when you are ready to do it up with the torque wrench. Trust me, it works brilliantly.

Four other tips for you:

1. There is this large flat washer that you have to install over the spacer on the shaft, but for some reason it is bigger than the spacer, and so tends to get misaligned. Stick it on with a dab of grease to keep it in place. Mine got in wrong, and a few hundred miles later it shredded itself and half of it ended up in the oil sump in multiple pieces and shards, stuck to the magnet. No serious damage, but I did have to pull the whole thing apart again. Big PITA.

2. If you take the sprague clutch out, make bloody sure you git it back in the correct way. After my second pull-apart to replace the washer, I got that wrong and the sprague wouldn't release, so the starter stayed engaged after the motor started. Bah!!!!

3. When you apply the gasket goop to seal the side cover, apply it to the engine side, not the cover side. That way you have less chance of messing it up as you align the cover upon reassembly.

4. If you have never taken the left side cover off before, be aware that one of the screws is hidden under the rubber boot of the clutch cylinder. I missed that one and was THIS CLOSE to trying to use a puller to remove the cover, since it wouldn't come off. That would have been an expensive mistake.

There, aren't you glad I such a shit mechanic, so you can learn from all of my mistakes?
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