Rotor Removal - 1983 GS100E

[Guest]

I need to repair my starter clutch(aka Sprag Gear) on my GS1100E.

So I did what I thought was the right thing, and bought myself a removal tool.

But no matter what I do, the rortor will not come off. I have hit it with my air gun repeatedly, and it will not budge. I tried heat(a propane torch for about five minutes time), I tried PB Blaster as well. Still no joy.

Is there a secret to removing the rotor? Do I need a bigger air gun? Do I need to hire the incredible hulk?

Thanks so much for reading my post. I am at my wits end.

[Agemax]

tighten the puller up as tight as you can get it, then give it a good whack on the end with a BFH. do not use to much heat. tighten a bit more,whack it again. do it a few times then get your impact gun on it.(make sure the gun is set to do up, and not undo!)

[chef1366]

BFH? Blunt force hammer?

[hampshirehog]

BFH? Blunt force hammer?

That is the most polite term I have heard for it........

Adrian was using anglo-saxon language.

[posplayr]

Depending upon whether you have a big guy avaliable here are my suggestions having done the same a few times:

• Use MAP gas not propane. It is hotter and will help concentrate the heat rather than a longer heating period that gets magnets hotter
• Heat the end of the rotor only (watch for the rotor magnets).
• Use two large breakers, one under your feet the other using both arms (like a dead lift) this works better than two people
• I have ruined my puller tool and had to rework it with a larger bolt.
• Trust it really is a Biatch but it will come off.

This is the tool I stripped and reworked for a larger bolt.

[chef1366]

That is the most polite term I have heard for it........

Adrian was using anglo-saxon language.

Oh duh........

[Agemax]

BFH? Blunt force hammer?

Big Friendly Hampshirehog

[CCM911]

Great advice. I was totally worried about heating the magnets up, so I am glad that was mentioned. This is so hard.

And to add insult to injury, when I hit the bolt with a BFH, it deformed a bit, making the socket hard to get on or off.

I am so p*ssed off at this point.

I think I may try using leverage in the form of big pipes over the end of my wrenches.

[CCM911]

Got it!!! You guys are the best!! Heat, combined with a BFH did the job.

I can't believe it, all three bolts were sheared off. Is this common? Now do I have to use the factory bolts, or can I pick them up at the local harware store?

Also, would drilling be the best way to get the snapped off pieces out of the rotor?

I really appreciate all the help. This board rocks!!

[chef1366]

I would use Suzuki parts.
Try a reverse drill bit to get them out.