XT600e Flywheel removal

[marcus0958]

Hi
New to this forum as (although) I have had my XT600e for six years or so I have never had any problems with it. Unfortunately in order to replace a corroded exhaust stud I had to remove the head with the engine out of the bike. When replacing the head I realised I had to line up the timing marks on the cam chain cog which are behind the flywheel as I don't think the correct marks are the ones through the inspection cover. Phew, so the long and the short of all this is that I cant get the flywheel off. I have seen previous posts about them being very tight and all sorts of suggestions which I have tried. I have broken three pullers so far and still it wont budge. It is a lowish mileage 2002 XT600e. I have used harmonic pullers that have snapped or threaded including one from Yambits. Just asking on the off chance that someone has another idea that no one had tried before.

[turboguzzi]

you are going to beat a record for the most complicated rusted exh. stud fix....


nobody removes the flywheel to time a cam, simply not needed...

so not sure what you think youll achieve by removing the flywheel.... there are no secret marks there that will help time the cam


just find TDC and drop the cam in place, if the marks are off, then you just jump the chain on teeth of the cam sporcket.

[marcus0958]

In the manual there is a diagram where there is a mark on the crank cog and a mark the casing that have to be lined up with the cam cog in the head all lined up. If its just a case TDC then thats what I will do. Its just that it doesn't look like that in the manual. But thanks anyway, I will and line it up without the flywheel coming off.

[turboguzzi]

yep, the punch mark on the cog is TDC, god knows why the manual covers only a complete engine rebuild and doesnt explain you dont need to remove the flywheel.... it's not the only stupidity there!