DISASTER!

[nissbird]

Oh no * news, my bulldog will not shed it's flywheel!
Having tried removing it myself and failing I gave it to a really good garage to remove the offending article, only for them to contact me later and tell me they could not get it off either. They put it back together and replaced the oil without any charge, the guy at D & R Motorcycles Hereford was quite "put out" that he couldn't remove it.
Now the only way to get it off without destroying the end of the crankshaft is to cut it out.
I can still ride it until the starter clutch finally gives way but I am gutted.

[WullDee]

Hey Phil,
bad news ...
We got a similar case lately in this board:
Demontage Polrad

It's an entry in german, but maybe you like to get the 7th topic (by TR1.Maschinfahrer) translated.
I'm sorry I don't know anything about working on motors ... but maybe the description is sufficient to help you / your mechanic ...

[nissbird]

Thanks Wulldee,

The items mentioned in that post have all been tried to the point of destroying the end of the crankshaft.

Do you know anyone who might have a flywheel for sale? I could have the old one cut off?

Regards
Philip

[WullDee]

Hi Phil,
are these the desired parts?
Flywheel 129€
Flywheel 200€
Unfortunately I don't know whether a member of the board has one to sell ...

[nissbird]

Yes they are the right items, I shall discuss with the garage about cutting the old one off and then buy a second hand flywheel, if you could ask some of our friends in Germany I would be very grateful.
Regards
Philip

[Big Ade]

Philip

Sorry to hear about your woes, the dog's engine is generally pretty well bullet proof and mine has sat at 6,800rpm for miles trying not to lose sight an FJ1300, 1200 Bandit and BMW 1200 when we went to Italy.

You know of course that thr Bulldog shares its motor with the Dragstar so it might be worth doing a trawl to see if there is a Dragstar bottom end on the cheap.

See you for Treffen 12? The Wales jaunt didn't happen and the weather is moving against us now so looking like 2015 for a long run.

Good luck with the motor.

Cheers

Ade

[WullDee]

... if you could ask some of our friends in Germany I would be very grateful

With pleasure: Polrad (Flywheel) gesucht

[eternum]

Now the only way to get it off without destroying the end of the crankshaft is to cut it out.

Did they already try to heat the flywheel in the immediate vicinity of the fitting with a acetylene-oxygen torch while applying force with the puller (and of course tap on the central bolt of the puller with a hammer)?
Making use of a strong thermal gradient is often a solution for "difficult" situations.
Most of the time applying a small (but intense) amount of heat is enough (without burning something).

A Mini-Ductor is flameless, does most of the time not belong to the "standard" equipment, and would heat the crankshaft instead of the flywheel. But probably the videos will show what (intense) heat can do...

[BBvideo 425,350]http://www.youtube.com/watch?v=_YO_snrzYrs[/BBvideo]

[BBvideo 425,350]http://www.youtube.com/watch?v=litvs7yX7RQ[/BBvideo]

[Lonedogg]

Almost given.
when you consider what a train station costs

https://www.google.de/search?q=Mini+Duc ... d=0CAgQ_AU

[Axman]

..and it´s too small to fit over the flywheel..

In the German part we have another suggestion : use "Ice-Spray" on the end of the crank...then give it - the flywheel.. - a healthy whack with a copper-hammer and it should pop off...it should..

Keep us posted

Axman

[eternum]

..and it´s too small to fit over the flywheel..

But they also have a "Bearing Buddy": 41" long (approx. 104 cm). That should be long enough.
But yes, it is (much) to expensive if it's used only one time ($395.00 including Bearing Buddy in the US, 110V ).



But there are now two much cheaper alternatives given:
- Ice-Spray
- an autogene torch

Hopefully the problem can be solved this way.

[nanno]

An oxy-torch is the answer. Use a very small jet (#5 or less), * in the puller and heat it up the point where it starts to discolour and it'll pop right off. Did just that with two very, very stubborn flywheels (of which one actually managed to kill the end of a crank, because the the nut (!!!) exploded, because of all the pressure!)

It turned out, that somebody hammered an imperial woodruff key into the milled slot...

Cheers,
Greg

[nissbird]

After the excellent advice above I have decided not to cut the flywheel off and have dis assembled my Bulldog ready to have another go at extracting the flywheel using the methods explained.

The motorcycle garage I used did try this method but failed. I shall continue the treatment until it does come off.

Question: Where should I strike it with a mallet?

Regards

[nissbird]

Is "Wurth Rost Off" the cooling spray to use?

[30°]

Is "Wurth Rost Off" the cooling spray to use?

Liqui Moly Kälte-Spray 400ml

take this or google search and related products!


Gruß
Christopher