Kicker part 2 and Rotor

[Dekon]

OK, so a few questions, I have not been able to get the kickert off the shaft , been trying for the last week. Every day spraying it do with Liquid Wrench, SeaFoam Penatrating Oil, etc., nothing, the thing won't budge. I have even, as a last resort, hit it with a torch. I did not get it red hot, I was afraid I would do more damage then good. I can not ge a puller due to the clearance around the shaft. I was thinking, if I take an impact wrench and a large enough socket to go over the shaft and give a it go on the kicker boss, maybe it will loosen the kicker. What do you think? Also, I took the left side cover off and the rotor is all rusted, is this going to be a problem? The nut and the flange on the rotor look like brand new, absolutely no rust on them. I am confused about that situation.

[KDXGarage]

How much/little clearance is behind the knuckle??

[pumpguy]

See if you can find a tool called a "Bearing splitter". These come in various shapes and sizes and are used with a screw type puller to pull bearings off shafts where there is only minimum clearance behind the bearing. A combination of pressure from the puller's screw and shock from a few careful hammer taps on the puller's screw will usually start things moving. An example is OTC Tools # 1123. Another example of a larger one is Kawasaki's Bearing Puller #57001-158. Hope this helps.

[Dekon]

How much/little clearance is behind the knuckle??

It is not so much the clearance behind the knuckle as much as clearance to where the clutch cover mounts.

[Thrahl]

Can you get a small pickle fork behind it?

[KDXGarage]

no way to get a 2 arm puller behind it?

[Dekon]

The pickle fork might work.

[Dekon]

no way to get a 2 arm puller behind it?

The problem with a two arm puller is that the back of the knuckle is radiused and the arms will not grab.

Anyone know what size flywheel puller I need to remove the flywheel?

[pumpguy]

I see what you mean. Should have checked mine first. If you rotate the kicker about 30 degrees counterclockwise, you should have enough room to use a small 2 jaw puller with the jaws at 6 and 12 o'clock. You will probably need to grind down the jaws to fit but don't be afraid. Decent quality puller jaws are some tough steel and won' break. At least mine haven't in several decades of use.

[KarlP]

I had to weld a puller to the kicker once on an old bike.
The "puller" was actually two pieces of 1/4" by 1/2" band iron and a 1/2" nut. I took a piece of 1/2" all thread and ground a point on it to push on the shaft.
The funny thing as that after all that fabrication and welding the kicker came right off. I used channelocks on the threaded rod. I think the heat of welding is what loosened it all up.

[the machinist]

Go to a car place that rent's tools, rent a chevrolet power stearing pulley puller. This should do the trick.
-Matt