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Old 01-13-2010, 09:13 AM   #1
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Sled: 96 ZR580
10-11 Mileage:
09-10 Mileage: So far, 380
08-09 Mileage: maybe 200
07-08 Mileage: 300
2010 Mileage: 200
2009 Mileage: 300
2008 Mileage: 400
On my 96 ZR580, I need to get the stator out for rewinding. So it took off the recoil, and have good access to the flywheel. Put my flywheel puller on it and cranked it tight, and no go. The flywheel is not letting go of the crank end. I applied heat with my heat gun while the puller was on there and also no go. I may try using a hobby style small flame propane torch.

Anyone else have similar experience trying to get the flywheel off?
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Old 01-13-2010, 09:36 AM   #2
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Sled: 96 ZRT 600, 98 Cougar M/C
08-09 Mileage: 5
07-08 Mileage: 500
06-07 Mileage: 400
Make sure that the puller is square to the flywheel so it is pulling straight out from the end of the crank. As you say, wind up the puller bolt tight and then wrap straight in on the puller drive bolt.
That is the method desribed in my Cat manual and the way I'v removed every flywheel.
Heat can be hard on magnets and the adhesive that bond them (when used) to flywheel.
I recommend spraying Seafoam Deep Creep (a great all-around shop spray) at the flywheel/crankshaft interface. The penetrant may not be able to creep into a tight tapered fit between the flywheel and crank but it may help.

good luck
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Old 01-13-2010, 09:54 AM   #3
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Tighten the center bolt of the puller as tight as it will go to the crankshaft. Then take and wrap on it with a hammer or if you have a impact use that & it should pop right off. DO NOT hit it hard or you will break the magnets. Also DO NOT use heat as you will melt the glue that holds the magnets in. It usuallhy does not take much to get the to pop loose but just tightening the puller will not do it usually. It takes a little vibration to jar it loose. Good Luck.
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Old 01-13-2010, 10:13 AM   #4
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Sled: 99 TCAT
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Having the puller true to the shaft an flywheel is very important
thats why the puller made for flywheels work so much better than steering wheel or dampner pullers
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Old 01-13-2010, 05:06 PM   #5
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Sled: 96 ZR580
10-11 Mileage:
09-10 Mileage: So far, 380
08-09 Mileage: maybe 200
07-08 Mileage: 300
2010 Mileage: 200
2009 Mileage: 300
2008 Mileage: 400
Thanks, I will try that. I do know on my last attempt I did not have the puller square to the flywheel so I'll do better this time. Also, I'll remove the tub plug so I can get an extension on the puller rod and get a good wack at it!
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Old 01-14-2010, 06:00 AM   #6
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Sled: 97 ZR440, 09 Z1T SP
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im in appleton and have a puller for these sleds if you cant get it true to the flywheel i can lend you my puller if need be, let me know
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Old 01-14-2010, 09:35 AM   #7
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Join Date: Mar 2009
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Sled: 96 ZR580
10-11 Mileage:
09-10 Mileage: So far, 380
08-09 Mileage: maybe 200
07-08 Mileage: 300
2010 Mileage: 200
2009 Mileage: 300
2008 Mileage: 400
Thanks Kelly!! Nice to have the local support. I'll send you pics of my AGLT mods when I'm done with it, I just found a set of 18" Fox clicker shocks with reservoirs for it on craigslist. But this weekend I'm sledding with friends up on the trails around Wabeno/Pelican Lake area on a friend's sled.

Hey, that pic of you with the BIG brownie, by chance was that on the Branch river by the golf course? It sure looks familiar. That must have been one FUN catch on a small river!!
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Old 01-14-2010, 12:13 PM   #8
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its just down the road from there by the other brigde but yes it was a blast cause i caught it on a 5'6" UL rod with 6lbs test lone. haha let me know aboput that puller it works sweet i just used it on my 96 580 efi and worked like a charm and fit nice and tight to the flywheel.
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Old 01-14-2010, 10:52 PM   #9
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Sled: 96 ZR580
10-11 Mileage:
09-10 Mileage: So far, 380
08-09 Mileage: maybe 200
07-08 Mileage: 300
2010 Mileage: 200
2009 Mileage: 300
2008 Mileage: 400
HA!! I got it out!! I was frustrated with the so-so puller I bought from Auto-Zone. Then I remembered I had one of my dad's old pullers (he was a mechanic) buried in my tool cart. Set it up on the flywheel and cranked it tight, it was much closer to the flywheel than the other one, and thicker too. One hard hit on the center bolt with a hammer and it popped free!! WHOO HOO!

Now I can move on with getting the beast running right!

Time to PM Blaine!
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