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Need Help, Flywheel Removal 86 CMX250

52K views 199 replies 23 participants last post by  charlieinflint  
#1 ·
I am trying to remove the flywheel from the 86 250 project motor because the starter clutch needs attention. I have 2 different wheel pullers but they won't fit properly, I am having to rig up some 1/4 inch all thread rod to go thru the holes in the bottom of the wheel. I'm assuming the wheel is a slip on with a key...is this correct? I was trying to put some heat on the shaft but I'm afraid I'm going to melt the plastic around the magnets. Anyone got any advice on this? I have the manual and it isn't any help it just suggests a honda flywheel removal tool which I don't have. I'm surprised but my Clymers manual doesn't have any info at all that I can find. Regards, Chef
 
#139 ·

How much of this can I cut? Of course not the gear, but I've been sticking mostly to the bowl, can I go further? It would make a better split. I'm going to take a chisel to it after I've got a slot down it. Hopefully.

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#144 ·
The bobberizers friend, the sawzall might work. You'd have to be careful with it though.
 
#152 ·
Oh no... I cut the crank.... but it's off.


Shelley took a look at it (decades of airplane engine/flight engineer experience so I tend to trust her judgement) and said it would be fine.

Still it upsets me that I cut into it.

The chisel behind it got it. Wish I would have thought of it before hand! But I hit it a bunch too.

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#154 ·
now, we just wait for bikebandit to ship the seal (I originally bought the wrong one, I bought the one for the shifter) and then Duckster's flywheel should be here next week.... and that gives me time to clean the oil filter.

And put red threadlocker on everything. ;)
 
#158 ·
The little button that holds the position of the flywheel and your ignition timing seems OK.
So do we conclude it was RUSTED ON? Hard to imagine how it could have rusted unless the thing was dunked and never got dried
 
#160 ·
Yeah, that was the main concern (and also why I didn't decide to go the "easy route" of cutting where the key goes, less material to cut).

There's something else on there, it might be red thread locker that got wet? I'm not sure. There's more than rust on it. But I can't tell what it is. I'm just going to clean it, de-burr it, and hope for the best after I put in the new seal.

The woodruff key slot on the flywheel looked a little banged up (from before me banging on it) which might have been something.
 
#165 ·
Well the new one you're getting has less than 1000 miles on it and never saw any loctite or rust. and congratulations getting the old one off.. I hope your crank bearings have survived OK.