Page 1 of 3 123 LastLast
Results 1 to 10 of 22

Thread: What puller to remove the magneto flywheel on a gs450?

  1. #1
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default What puller to remove the magneto flywheel on a gs450?

    The service manual says part 09930-30102 ... which is a sliding hammer type puller. People in this group have stated that type tool wasn't effective on their rotor covers and also not the 3 jaw puller types. On ebay I see vendors selling a 38 mm threaded puller claiming it will work for the gs450 ... among many others. Also, I have heard users say they used a hardened bolt to pop the magneto flywheel cover. This part seems to have several names! Some Suzuki's can use the rear axle (or swing arm bolt?) as a puller. I can never find specific information for the GS450. My preference is to find the correct puller for MY bike and order it ... and then pull the stator left side cover off to start my investigation of the starter clutch intermittent problems I have with locking up and driving the starter motor to dangerous high rpms. I have watched repair videos for the one-way steel rollers to the crankshaft and I am pretty sure that will be my problem when I finally get in there to inspect.

    So if someone here has a proven type puller to get the magneto flywheel off .... please share that part number with me and how to order it?! Thanks in advance.
    Dennco2
    1985 GS450
    Stock condition and a work in progress


  2. #2
    Join Date
    Aug 2010
    Location
    Sebago,Maine
    Posts
    8,639

    Default

    Your setup should be like my 650......you need a 16mm bolt that threads into the rotor (after you remove the rotor bolt) and pushes on end of crankshaft to pop rotor off. I would not use a sliding hammer type puller...the plain crank bearings might object
    something like this eBay item...
    https://www.ebay.com/itm/27mm-28mm-1....m46890.l49292
    1981 gs650L

    "We are all born ignorant, but you have to work hard to stay stupid" Ben Franklin

  3. #3
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default

    Quote Originally Posted by tom203 View Post
    Your setup should be like my 650......you need a 16mm bolt that threads into the rotor (after you remove the rotor bolt) and pushes on end of crankshaft to pop rotor off. I would not use a sliding hammer type puller...the plain crank bearings might object
    something like this eBay item...
    https://www.ebay.com/itm/27mm-28mm-1....m46890.l49292
    I ordered the puller bolt recommended above ... but it was too large. 14mm was the correct fit. First, I struggled to get the center 17mm mounting bolt off. With chain vice grips to hold the outside of the flywheel, the bolt finally came out. Today I attempted to pop the rotor flywheel off by threading in the 14mm puller bolt ... but no luck so far. Using a breaker bar, I am afraid I will strip the inside threads of the flywheel if I apply more force. There appears to be 3 screws attaching the flywheel (from the inside out!) I can NOT get to .. until the flywheel is removed. Are those 3 screws holding the flywheel on the shaft and preventing removal of the flywheel??

    I just want the flywheel off .... so I can inspect, clean or replace the 3 bearings called the starter clutch ... which seems to grab the shaft intermittently.
    Dennco2
    1985 GS450
    Stock condition and a work in progress


  4. #4
    Join Date
    Aug 2010
    Location
    Sebago,Maine
    Posts
    8,639

    Default

    Those 3 screws go to starter clutch....leave them alone . You need to buy/borrow/steal an impact wrench ....the twisting blows from impact will slowly drive the 14mm bolt into crankshaft and pop the rotor free..eventually

    edit: best to use a 6 point socket
    Last edited by tom203; 04-10-2021 at 06:51 AM.
    1981 gs650L

    "We are all born ignorant, but you have to work hard to stay stupid" Ben Franklin

  5. #5
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default

    Finally had success popping off the rotor flywheel off the tapered crank. It was very stubborn and we tried impact wrench, banging with a rubber mallet, a breaker bar. It finally gave up. Anyway, for an 85 GS450. a 14mm hardened metric bolt is all that is needed ... plus a impact wrench, breaker bar and lots of patience. Thanks to John Park and Tom203 for great suggestions. When the parts don't come off with reasonable effort, one starts to get nervous and think your screwing up somehow!
    Dennco2
    1985 GS450
    Stock condition and a work in progress


  6. #6
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default

    So after finally popping off the rotor flywheel, I was able to inspect the stator windings and starter clutch parts. The stator coils looked quite dark indicating it has gotten very warm during it's life time but no windings seem burned or out of normal. Last time I checked the charging voltage, it was very low .... but I will check again when I get the engine running again today hopefully. Also, 2 of the 3 steel starter clutch bearing had fallen out of their position .... but looked in pristine condition.

    When attempting to reinstall this assembly back to the crank, I ran into another problem. My 12mm rotor bolt would not thread back on the crankshaft. Somehow the threads had been buggered up. So I had to get a 12mm tap with a 1.25m thread size to clean up the crank threads .... then the bolt went right on. Finding the correct thread size on the internet to get the right tap ... proved to be difficult. Also, the correct rotor flywheel puller bolt size is 14mm x 1.5mm ... for the 450.
    Dennco2
    1985 GS450
    Stock condition and a work in progress


  7. #7
    Join Date
    Aug 2010
    Location
    Sebago,Maine
    Posts
    8,639

    Default

    If your stator windings appear toasted, I’d opt for replacement...especially if you noted low voltage readings in the past. Here’s my previous stator...note the small cooked section. This was enough to prevent a charging voltage greater than 13.5 at any rpm.
    4FE47BFA-D112-44BA-986C-FEAE26E2D990.jpg

    edit: hopefully you noted the preaching about getting a SH-775 r/r
    Last edited by tom203; 04-16-2021 at 04:50 PM. Reason: Further
    1981 gs650L

    "We are all born ignorant, but you have to work hard to stay stupid" Ben Franklin

  8. #8
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default

    Quote Originally Posted by tom203 View Post
    If your stator windings appear toasted, Id opt for replacement...especially if you noted low voltage readings in the past. Heres my previous stator...note the small cooked section. This was enough to prevent a charging voltage greater than 13.5 at any rpm.
    4FE47BFA-D112-44BA-986C-FEAE26E2D990.jpg

    edit: hopefully you noted the preaching about getting a SH-775 r/r
    I took a picture of the stator when it was off. Do you see anything abnormal in this pic? stator4.jpg
    Dennco2
    1985 GS450
    Stock condition and a work in progress


  9. #9
    Join Date
    Aug 2010
    Location
    Sebago,Maine
    Posts
    8,639

    Default

    No it looks ok....But testing it while running it is the only way to be sure
    1981 gs650L

    "We are all born ignorant, but you have to work hard to stay stupid" Ben Franklin

  10. #10
    Join Date
    Aug 2016
    Location
    bothell, WA
    Posts
    153

    Default

    What is the best source to get the SH775 part at a good price? Any clones knockoffs to be aware of?
    Dennco2
    1985 GS450
    Stock condition and a work in progress


Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •