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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 15 May 2010
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rotor

i have a 2003 xt600e and i need to get the rotor off to fit a new cam chain.i have tryed a puller and i have tryed heat.( i think i have melted the resin in the magnito) but it still wont come off .any ideas???? do i need to buy a new rotor ???
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Old 15 May 2010
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Big puller, and a big, big hammer...You need a lot of force.

Tighten the puller very good, then heat, and a big gonk with the hammer. Me and my buddy had to remove his flywheel, and we used a big slegdehammer with a 1meter long grip on it. (just to give you an idea of the size and the force)

We took a pic, but I cant find it. I believe i posted somewhere inhere...

Dont know if it relates to you're problem tho'
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Old 15 May 2010
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Don't heat it - You'll burn your windings to a crisp!!!

Go to your local bikeshop and tell them you need a Yamaha flywheel puller, they are less than a tenner and are the tool for the job.

You need 2 spanners and a bit of brute force - no heat or hammers!!!

Not everything can be fixed with a hammer and a screwdriver...
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Old 16 May 2010
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Well then I know, cant transfer pulling the flywheel, to pulling the rotor

No hammertime i guess
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Old 19 May 2010
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what about the melted resin ? does it matter or do i neet to get a new rotor ?
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Old 19 May 2010
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i made a puller out out of 1 inch thick steel and tryed heat and tryed a hammer and had it that tight that i trashed a few boltes but it still wont move .any more ideas????
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Old 19 May 2010
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Get a new used engine?
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Old 19 May 2010
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Axle bolt

As Tenere Tom said a proper puller will do the job a whole lot easier.

But having said that and this may sound strange but on off road bikes the axle bolt more often than not has the same thread on it as the rotor. just screw it in and you can use that in a side hammer type arrangement.

Strange I know but has worked for me a couple of times when I only had basic tools available.
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Old 20 May 2010
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Hi Dave,
I recently also had a hell of a time removing my magneto to renew the Camchain.
I used a standard puller worth about 10 quid. Ground the end of the puller centre bolt to a taper as there was no room for the tapered attachment which came with the puller. Then using three 8.8 tensile bolts I attached it & tightened the centre bolt with a 2 ft power bar !! Then tried hitting the centre bolt with a 3 lb hammer. Then tried heating the magneto. Eventually it came off after much hitting with the hammer & some heat.
End result was puller still in one piece & not bent suprisingly, but threaded end of crankshaft bent somewhat & thread damaged due to the puller centre bolt trying to go off-centre from the force involved.
.
P.S. During the operation I had to fit a short piece of heavy wall pipe over the threaded end if the crankshaft to the keep the puller centre bolt central.
Also, when refitting the magneto ensure the taper is dry (no oil).
If oil or grease is on the taper, being a lubricant that will allow the magneto to be pressed on further than it is designed to & therefore even harder to remove next time.
Hope this helps & good luck !! you'll probably need it.
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Old 20 May 2010
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you have to build something like this: (see pictures)

it will take some time and afforts but you will be sure to succed, avoiding to destroy your loved engine. Project by LELE74
Attached Thumbnails
rotor-pic1.jpg  

rotor-pic2.jpg  


Last edited by cyberzar; 20 May 2010 at 14:51. Reason: credits ;-)
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