xt600 rotor removal / starter clutch replace
As I have the LH engine casing off my IVJ xt600 for stator replacement,
I would like to take off the flywheel, and check/replace the failed starter clutch, a job that I have been avoiding for a while. ( The starter clutch had become unusable, and would sometimes jam, rendering the kickstart unusable, so I had previously removed the connecting gears via the starter gear cover ) I have since obtained a secondhand replacement clutch to fit.
I shall be employing a snap on puller, ( similar in appearance to the halfrauds item ) and will make up three suitably sized m8 bolts to secure it to the flywheel.
I have several concerns however, and perhaps those with experience of this job could comment.
Firstly, my puller has a pointed tip to locate in end of crankshaft. should i use this or make up a flat spacer ? I ask as i have seen images online of splayed crank ends after attempts at removal.
Secondly, I need to lock up the engine in order to release the nut on the end of the crank. The engine is still in the bike. other than removing the
right hand casing and putting a copper washer in the gears there, is there an effective way of doing this ? I don't have access to a rattle gun, and envisage using a breaker bar, but it will need to be locked solid.
Thirdly, once the puller is in place and ready to go, what is the favoured
method of releasing the rotor ? ( heat / hammer/ tighten wd40 etc & in what order )
To be honest I would rather leave the job undone than risk bending the crankshaft or damaging the bearings.
Look forward to your insights
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