How to Remove the Flywheel
On 2 Stroke Dirt Bikes

Below we'll show you how to remove the flywheel (Also referred to as a rotor) from a 2 stroke motorcycle, as well as we'll show you where you can get a flywheel puller, as a specialized puller is necessary for removing the flywheel without inflicting damage to expensive parts.

As you may already be aware, 2 stroke dirt bikes have electronic components behind the flywheel and removal of the flywheel is often necessary to gain unobstructed access to the left hand crank seal for inspection or replacement, as well as having the flywheel out of the way will allow you a close visual inspection of the electronics housed behind the flywheel, or will enable you to split the cases for crankshaft or transmission related service operations.

When working on a 2 stroke motorcycle with a run on condition or a high idle, the problem can occasionally be tracked to a leaking LH crank seal which is essentially a vacuum leak allowing unmetered and unfiltered air into the engine which can ruin a perfectly good piston and cylinder (among other parts) in no time.

On the bikes which won't start at all, or are experiencing electrical issues such as intermittent open circuits (no continuity), removal of the flywheel will allow you a close visual inspection of the stator and any lighting, or exciter coil(s) as these occasionally develop loose connections at the solder joints resulting in intermittent misfires, lights that are dim or have no lighting power at all, or a motorcycle that loses spark completely.

Be Sure You Check the LH Crank Bearing for Wear

Once you're determined to remove the flywheel, before actually removing the flywheel it's wise to check the left crank bearing for any wear, as worn crank bearings will require replacement and checking these is usually easier with the flywheel installed as it will allow you more to grasp than only the end of the crank.

How to Remove the Flywheel

The flywheel is pressed to the crank via the center nut, with a tapered fit on a keyed shaft, and removal of the flywheel from the crankshaft does require a special flywheel puller, as no other type of pullers are suitable, and attempting to use anything other than a flywheel puller is sure to result in a damaged flywheel and / or crankshaft.

  • Begin by using an impact wrench, or a flywheel holding tool with a socket and ratchet, then loosen the nut in the center of the crank and remove the nut and washer.
If There's A Flywheel Weight Installed, Remove It Before Continuing.
  • With the nut and washer removed, ensure that the center bolt of the puller is backed out, then thread a flywheel puller into the flywheel (Likely LH Thread) until bottomed.
  • With the flywheel puller securely threaded into the flywheel, hold the outer part of the puller so it doesn't move, then thread the center bolt in against the nose of the crankshaft until tight.
  • With the flywheel puller threaded securely into the flywheel and the center bolt in contact with the crankshaft, hold the outer flange of the puller and tighten the center bolt with moderate force. (~50 - 80 lb -ft of torque if necessary)
  • If the flywheel does not come off upon tightening of the puller, using a brass hammer, strike the end of the puller using a sharp blow focused directly on the end of the puller, then re-tighten the puller and the flywheel should "Pop" and come off.

Once the flywheel is removed, the stator plate, along with the coil(s) and pickup(s) and all of their mounting hardware will be visible, enabling you to remove the fasteners securing the entire stator plate to the crankcase, ultimately allowing unrestricted access to the electronics and left crank seal.

Readers Rides
From Our Free Classifieds

Instantly See Your Dirt Bike Here
...& Remove It Whenever You Want Just as Fast

  • No Fees, Emails, Memberships, Passwords or Personal Info
  • Build Your Free Ad In Seconds & Instantly See Your Ride Live
  • Edit, Delete Or Renew Your Details Or Photos Anytime For Free
Advertising FAQ's

Q: What Happens When I Create An Ad?
A: Exactly what you'd expect, or hope to expect. An Ad just like these will be created based on the information and photos you provided, exactly as you provide it, Complete with your own User Interface (UI) for editing, removing or renewing your ad(s).

Q: How Do I Edit or Deactivate My Ad?
A: That's Easy, Just Click on the description where you want to edit it and make your changes on the live site.

Q: What Happens After 30 Days?
A: Your Ad and photos are removed from public view as one might expect and renewing any ad is as easy as editing or deleting it from your automatically generated UI.

Q: Do You Share My Info?
A: NO, And not only are you not sharing anything you wouldn't publicly share elsewhere, There's not enough $$ in the world to interest us in shenanigans or anything that would tarnish our image.

Q: Will I Be Spammed?
A: With Google's Captcha, Their eMail Spam defenses, the Quality of Our Visitors (Like Yourself) and Personal Moderation, Most Likely Not, however there's no telling since publicly posting a telephone number or other contact details can leave anyone susceptible to mankind even under the most stringent conditions.

Watch the Simplicity Of Adding Your Motorcycle Here but Hang Tight, There's a better version coming


You'll Cherish The Integrity Of This Moto Inspired Wizard

Please Correct The Fields Highlighted In Red

Mic Icon
📷Securely Select Or Capture Up To 4 Photos
Preexisting Photos Can Be Dropped Here & Preview Images Appear Here

Ads Auto Expire in 30 Days & Use Of Our Site Acknowledges Acceptance of Our Privacy Policy