***z400 Stator And Flywheel Bolt Replacement***...

[catdieselpow]

QUOTE (Quad82 @ May 10 2007, 06:05 PM)

I know it's an old thread. But it's still a very good one. I forget which member here told me about making a flywheel puller out of stock axel nuts. But thanks. I thought I came up with a good idea and wanted to share it. Before the KFX I had Warriors. Lots of them. Any ways, I had lots of Warrior specific tools. One was a flywheel puller. It's too small for the 400 and I no longer have a Warrior. But I have sold a few of them to friends. You know who gets to work on them! Well I had a thought to sell the puller on ebay to fund one for the KFX. As I looked at it tonight, I came up with the idea of welding the 38 mm nut on the smaller Warrior puller. It turned out perfect. It works on the KFX and the Warrior too. The Warrior's threads are further out on the crank than the KFX ones are. The larger 38 mm nut slides past the Warrior crank threads no problem. 1 Tool for both machines. Sorry for the long post. I just wanted to explain why I did it. Not the best weld or paint job. It's painted green to keep Bellsbub from stealing it!
[/b]

where did you get the 38mm nut I cant find one

[Quad82]

I looked every where too. No luck. This one is a stock 400 axel nut welded on. You can make two pullers from the axel nuts. But I would only use the larger of the two. More to work with and more threads to thread on.

[moondoggy]

Very nice thread... I actually did this on my quad back in 2005. what I havent found out yet was WHY it happend in the first place. A few months after I installed a dyna FS programmable rev limiter on it and some new tires and wheels that it happened to me....did anyone else notice it happend after any specific mod or just over time with constant abuse???

[camaro1976]

I am going to do this since I'm painting my covers anyway. Maybe also a Ricky stator and a Trailtech flywheel... But when you say the nut is right hand threads, that means lefty loosey, righty tighty? or the other way around. I could look at the threads when I have it apart, but if I get an answer on here sooner, that would help so I know ahead of time.

[camaro1976]

QUOTE (N.J.C. @ Apr 30 2005, 04:17 AM)

Once the flywheel breaks loose from the crankshaft be cautious, it will come off in a fast motion.[/b]

this should be changed to: once you have the puller cranked down pretty hard, you will turn it a tiny bit more and POW! the flywheel will come shooting off.
i almost crapped my pants and i would've landed on my ass if my car wasn't right behind me.



QUOTE (Camaro1976 @ Apr 1 2008, 11:03 AM)

I am going to do this since I'm painting my covers anyway. Maybe also a Ricky stator and a Trailtech flywheel... But when you say the nut is right hand threads, that means lefty loosey, righty tighty? or the other way around. I could look at the threads when I have it apart, but if I get an answer on here sooner, that would help so I know ahead of time.[/b]

its lefty-loosey if anyones wondering. you can't see very much of the threads so if someone didn't look closely they could turn it the wrong way.


and if anyone has the engine out, its a lot harder so heres what i did to help you out a bit. take a wood hammer handle and put it under the stator side case. screw the puller onto the flywheel and adjust a pipe wrench so that its pretty tight on it, now brace that on the workbench top. then take a long breaker bar and push down towards the bench and don't pull up.

[reverev313]

QUOTE (moondoggy @ Jan 21 2008, 02:33 PM)

Very nice thread... I actually did this on my quad back in 2005. what I havent found out yet was WHY it happend in the first place. A few months after I installed a dyna FS programmable rev limiter on it and some new tires and wheels that it happened to me....did anyone else notice it happend after any specific mod or just over time with constant abuse???[/b]

i also added dynatek not programmable rev limiter and k&n filter after 3 months all 6 bolt from the flywheel broke is this normal i do ride her hard i been look online and no answer on why hope someone can help dont want this to happen again shes only 5 months old i thought it was from down shifting to hard i dont know this is my first quad
2006 dvx 400

[gun1817]

THis is awesome .. really wish i would of found this last night before my friend tried impacting that 27 mm behind the 17mm .. can anyone tell me if that could of hurt anything?

THANKS A TON THESE FORUMS ROCK!

[Inglorious BSTRD]

no it wont hurt anything. Just go buy yourself a puller or make one, dont try to get it off without one or you will be buying a new flywheel!!

[camaro1976]

Originally Posted by gun1817

THis is awesome .. really wish i would of found this last night before my friend tried impacting that 27 mm behind the 17mm .. can anyone tell me if that could of hurt anything?

THANKS A TON THESE FORUMS ROCK!

Seems stupid but I would probably replace the key. I somehow broke mine when I was taking the flywheel but its up to you.

[gun1817]

how much is a puller? or where can i get one?

[johnboy]

great thread !!!!