OK, so I picked up a motor, well, it's one of those motors in a box.

Between the one I bought, and the bad one, I should be able to get one good motor out of the both of them.

So, looking at all the "specialty" tools needed, those of you that have done it, which ones are really needed?

I have done a couple SV650 motors when I was racing those, but I never split the cases.

THX

JJ in Pittsburgh

 

OK all, I guess I answered my own question over the weekend. I got one of the motors, the bad one, completely tore down, cases split, bearings removed, everything labeled, cleaned, bagged, etc.

There is one issues I am having with the flywheel/rotor. On page 3-16 of the manual, it states that I need the rotor removal tool. However, I have removed flywheels before, I have a universal removal tool/bearing puller that has removed these in the past.

This one though, won't budge, it seems someone prior to me has tried to "turn or twist" the flywheel off, I can see pipe wrench claw marks on the end, and the nut is stripped a bit where the pipe wrench marks are.

Has anyone removed these before, and do I absolutely need the tool? before I drop $50, I wanna make sure. I'll try to get a pic in tonight.

 

Get the right flywheel tool.Makes removing lot easier and no damage to flywheels. I had a drawer full of these at the shop to fit a lot of different Japanese machines.

 

Found the tool at a local Suzuki Jet Ski dealer.....

The rotor was tight, and the woodruff key was twisted, which tells me someone tried to turn the flywheel off, instead of the flywheel removal tool.

Anyways, after a breaker bar to tighten the tool, the flywheel popped off.

THX