I have a few motor rebuild questions for my Zilla?
How do you remove the clutch sleeve hub, my manual says you have to have a special tool? And the book says you have to have a tool to split the cases. I have plenty of tools but not these 2 specific tools. Is there a way around this? Or what you you guys done?

 

I have a lt250 and when I remove my clutch hub if the moter is in the bike put it in a high gear and hold the brake. You might need someone to hold the tires as well. this will put a lot of strain on the engine gears but I have never broke anyting in mine. if the engine is out of the frame put the spoket on and put the sproket in a vice. again this will put strain on the gears but this is the only way I no how to do it. I have never used the correct tools to split my cases. Just be gentle and don't pry it with a screwdriver. hope this helps. good luck!

 

Usually you can work the cases apart. The clutch nut will come right off with a impact gun. Just make sure your going the right way.

 

How do I get the magneto rotor off with out buy the "special tool" I got the nut off already. It should pop off but I can't get any thing in to pop it off.

 

Believe me!!!! It will not pop of!! You will need that tool. Being a machinist I made my own puller tool for the flywheel. I keep it close by and it works remarkably well. Even with this tool it doesn't pop off. It comes off with a loud bang. The tool has a left handed metric thread on the outside and a regular thread for pushing with a 1/2 in. bolt turned to a sharp point in the centre of the tool. I should market these things and make a killing even selling them at a fraction of suzukis price.[img]i/expressions/face-icon-small-wink.gif[/img]

87 zilla
87 Quadsport

 

I believe you norm, I stripped out my conventional flywheel puller after I made some mods, to it to fit. And that thing didn't move I'm takin it to my suz. shop tomorow Thanks any advice will be appreciated.

 

Heat up the flywheel with a torch, it will pop off with the puller.