Flywheel Removing Tool Question

[kichigai]

Hi have a 1983 GS1100ESD that started making a rattling noise. My guess is that it is coming from the left side cover. I did some research where people have suggested checking the starter clutch. After getting the magnito cover off, I place a chain wrench around the flywheel and was able to get the center nut off and am in the process of getting the flywheel off the crankshaft.

It looks like I will need to get special flywheel removing tool so I started doing some checking. The manual saids to use a rotor extractor tool # 09930-34911 which is now replaced with tool # 09930-34960 which I believe both are 35mm.

I did some checking on BikeBandit website and found two pullers both for the Suzuki GS.

Tool Part # 24833 or (6509644-001) is made by BikeMaster and is a 35mm puller with 1" internal depth. Cost is $34.67.

Tool Part # 24834 or (6509645-001) is also made by BikeMaster and is a 35mm puller with a 3" internal depth. Cost is $48.02.

Dennis Kirk has a flywheel puller too which is listed for a Suzuki GS Tool Part # 281967 but theirs shows it being a 38m x 1.5 RH External, Female (1" depth) Cost $67.99

Any suggestion on which tool to get?

Also, am I on the right track to check the starter clutch? So far visually, without removing the starter clutch it all look ok! It spin freely with a wrench when turned counter clockwise but engages when turn clockwise. The right side clutch basket nut is nice and tight when checked.

Any help would be appreciated.

[blowerbike]

buy an OEM puller for this bike(suzuki brand).
you need the small threaded puller for the large taper 83-86 1100/1150 16v..

[Guest]

http://www.thegsresources.com/_forum/showthread.php?t=123877&highlight=starter+button+rewire

Once you replace the broken bolts in the starter rotor, go to thread above and DO WHAT IT SAYS TO DO!. It will save you pulling that pesky rotor off again...
Curt

[rapidray]

Kich, you've been to my house, come use mine! For FREE!!! Ray

[blowerbike]

Kich, you've been to my house, come use mine! For FREE!!! Ray

hmmmm
sounds kinky

[rapidray]

You PERV!!! Ray.

[kichigai]

Thank you all for your reply!

Ray, I may take you up on your offer and give you a call. Thanks!

Kich

[kichigai]

I ordered a flywheel removal tool and like some of you, got the wrong one! I ordered the 35mm X1.5 from Bike Bandit which was listed as for a GS1100 but it was too big!
After doing some more research, I found out that the correct one was a 30mm x 1.5 Right Hand Thread 1" Internal Depth. The one I picked up was make by Heartland Products and sold through Amazon.com

http://www.amazon.com/Kawasaki-Suzuki-Flywheel-Puller-1-5mm/dp/B003N8DGQG

Not bad for $19.99
I have to say, for the price, the quality was good and it got my flywheel off! The dealer one was like $78.00!

I also picked up a Chain Wrench from Harbor Freight tools for $5.99 to hold the flywheel from spinning.

As you can see in the picture, the outer nut has some yellow colored locktight to hold the nut in place.

Next was installing the puller on the male threads on the center hub.

The flywheel did not come off at first! I eventually had to heat the center hub a little bit with a propane torch and then it finally poped loose!

I took some pictures for reference in case anyone else needed to do this!







Once I had the flywheel off, I found that two of my starter clutch bolts had sheered off and the last screw was loose which cause some internal damage. I decided to just order a new one from Bike Bandit.

[blowerbike]

the hex on the puller can be used to keep the rotor from spinning while being removed.

[bigbill808]

i ordered the tool from amazon you listed. it is the wrong size!! for the '79 gs1000 i have, it needs the 35mm tool not he 30mm. so anybody needing one for their bike 1978-1982 order the 35mm. heartland tools are great to work with, they are letting me return the one i bought for the correct one, minus shipping of course.

[blowerbike]

who listed what tool wrong?
this thread was about an 83 1100 16 valve.
pre 1980 8 valve can use a bolt to push the rotor off...not a puller.

[bigbill808]

i am sorry.... i didn't see that it was for a 1100 16v. please except my apologies...

[bigbill808]

just an fyi, the pre '80 models do require a "puller". a bolt will not "push" it off. i just ordered the new 35mm tool from heartland tools and will post pics as i remove the starter clutch.

[blowerbike]

i don't have a pre 80 rotor here but using a "swing arm pivot bolt" to push the rotor off has been discussed before.
anybody else want to chime in or am i loosing my mind?
you know what???
i am right.
yes you can buy a puller but you can also use a bolt to push it off.
free is nice!

[bigbill808]

i gave your idea a valiant effort.... but no luck.