Flywheel removal

Message

BigE · #1 Post by **BigE** » Tue Mar 31, 2009 3:24 pm

I am trying to remove the flywheel on my Falco to get at the sprag clutch. I've found the genuine Aprilia tool for doing this on AF1 but $50 seems a lot for what is basically just a bolt! Does anyone know what the thread size of that bolt is?

Cheers

D-Rider · #2 Post by **D-Rider** » Tue Mar 31, 2009 3:51 pm

Here's how Pierre did it (from the archived forum):

http://www.apriliaridersite.com/viewtop ... ight=sprag

.... the flywheel removal does sound a bit dramatic .... but with Pierre involved we'd expect no less

.... oh, and sorry, that doesn't actually answer the question about thread-size ....

BigE · #3 Post by **BigE** » Tue Mar 31, 2009 7:12 pm

Thanks D-Rider

I had already read Pierre's method. I've got as far as removing the flywheel. Pierre says he modified a 3 leg puller to get the flywheel off, but doesn't say how it was modified. I have a puller but can't see how to modify it to make it work - Help!!

The other option is the genuine Aprilia tool (expensive) or a big bolt - hence the question about thread size. Can anyone help?

Cheers

D-Rider · #4 Post by **D-Rider** » Tue Mar 31, 2009 8:03 pm

BigE wrote:Thanks D-Rider

I had already read Pierre's method. I've got as far as removing the flywheel. Pierre says he modified a 3 leg puller to get the flywheel off, but doesn't say how it was modified. I have a puller but can't see how to modify it to make it work - Help!!

The other option is the genuine Aprilia tool (expensive) or a big bolt - hence the question about thread size. Can anyone help?

Cheers

You could always send Pierre a PM to ask him - even if he's not looking at the forum, it will send him an email to alert him.

Hopefully he'll be able to answer you or someone will come up with the thread size.

Pierre · #5 Post by **Pierre** » Wed Apr 01, 2009 8:49 am

I couldnt get a big enough threaded bar before my patience ran out, hence the flywheel puller. I wouldnt recommend it as i damaged the threads on the crank

But hey, who needs them anyway.

Cos of the rounded bottom of the flywheel the hooks of a normal puller keep slipping off as you tighten it. I cut 3 strips of metal and slipped them over the top of the puller to stop the top pulling inwards and hence and therefore stopping the bottom moving out. See artists painting below

I'm sure your local bolt shop will have something big enough. I'd rather spend 3 hours butchering something than walking 5 mins to the shop

Chabby · #6 Post by **Chabby** » Wed Apr 01, 2009 7:32 pm

Pierre - See artists' painting below! - Picasso from his cubist period I presume.

BigE · #7 Post by **BigE** » Wed Apr 01, 2009 9:59 pm

Thanks Pierre, for the artistic drawing. But your warning about damage to the crankshaft has put me off that method.

I have tried to find a suitable big bolt but M20 is too small and M24 is too big (and I am told there's no such thing as M22) also the pitch of both these looks too course.

So, I have ordered the genuine part for the ridiculous price of £39. I'll let you know how I get on when it arrives

Thanks for your help

paddyz1 · #8 Post by **paddyz1** » Wed Apr 01, 2009 10:33 pm

BigE wrote:Thanks Pierre, for the artistic drawing. But your warning about damage to the crankshaft has put me off that method.

I have tried to find a suitable big bolt but M20 is too small and M24 is too big (and I am told there's no such thing as M22) also the pitch of both these looks too course.

So, I have ordered the genuine part for the ridiculous price of £39. I'll let you know how I get on when it arrives

Thanks for your help

Can i borrow it

Chabby · #9 Post by **Chabby** » Wed Apr 01, 2009 11:59 pm

Used to be on old Hondas that the thread one of the wheel spindles (or was it swing arm?) was the same as the internal thread on the stator and could be used to pull it off the taper.

Don't suppose that's the case with flywheels on Prillas?

BigE · #10 Post by **BigE** » Thu Apr 02, 2009 7:48 am

[quote="paddyz1
Can i borrow it

[/quote]

Yes. But let me have a go with it first

BigE · #11 Post by **BigE** » Wed Jul 22, 2009 9:43 pm

The flywheel removal tool finally arrived. After 2 months! It was then a 2 hour job to get the bike going again

It's unbelievable that such an insignificant little piece of spring can completely disable the bike

What a great feeling when it burst into life again

Thanks to everyone who replied to my original post

And if anyone wants to borrow the tool - just get in touch

paddyz1 · #12 Post by **paddyz1** » Wed Jul 22, 2009 10:55 pm

I was only joking but will keep the offer in mind

thanks

D-Rider · #13 Post by **D-Rider** » Wed Jul 22, 2009 11:09 pm

Cheers "E".

Glad to hear it lives again

#14 Post by **mangocrazy** » Thu Jul 23, 2009 10:32 am

Hi BigE,

As a matter of interest, would it be possible to measure up the thread size (shaft diameter and thread pitch) of your supa-dupa new tool and post it up here as a reference?

I'm guessing that besides being a particularly weird thread size/pitch it's also been heat treated to make it stronger, but I'd still be interested to know...

sabestian · #15 Post by **sabestian** » Thu Jul 23, 2009 3:57 pm

Good idea mongo, also pictures for reference would be nice!

BigE, congrats on getting your bike to live again. How much did it all cost you and what exactly was the damage?