Hal,
Sorry I was non-responsive to your query. I
thought you might be want to actually shave the flywheel yourself.
I have done this job three times now; and it is not easy
simply because of the physical force required to remove a flywheel that is
well "stuck" onto a tapered shaft.
It would help you to have the factory manual. Cost
about $40. You need this to picture how everything should
look.
You need to remove the two left-side covers. The front
cover of the two will seem to be held on unnecessarily - it is the magnetic
force of the flywheel - it's
magnetized. With that, the flywheel is
exposed. You will lose about a quart of oil. Be careful not to allow the
cover to "hang" on its connecting wire - support it or unplug the
wires.
You will need a good flywheel puller, an air-driven 1/2"
drive impact wrench and two propane torches. If you don't have the
tools, you can't get the flywheel off its shaft. The flywheel is
attached to a tapered shaft by a nut, which is torqued to about 100 ft.
lb. Make sure the bike is in gear. Once you get the nut off,
you'll find that the flywheel is really stuck to that shaft. Talk to
Paul Venus. He just did it and swore it was one of the hardest jobs to
do. Figure a five hour job. You will need new gaskets for the side
covers.
I think it is important to use a good quality flywheel
puller. I use a Craftsman, which is guaranteed not to break. It is
important that the puller be exactly parallel with the flywheel. If canted
ever so little, it will pull the flywheel "sideways" further locking it onto
the shaft. I used a vernier caliper to measure the distance from the
puller arms to the face of the flywheel.
I think you can use some heat on the hub of the
flywheel. A gas torch is too much. A single propane torch is too
little. Use two propane torches and heat the hub until your spit
sizzles. Then get your air compressor psi up to max and use the impact
wrench to try to drive it off. A helper with a rubber hammer can
tap/pound on the flywheel when you are applying the impact wrench. The
flywheel will POP off with a bang - so be careful and have a pile of towels
below to catch it.
You will have to remove and reinstall the starter clutch
assembly, which is mounted to the back of the flywheel. Note, Yamaha has
"crimped" the mounting bolts by means of a drift. The mounting bolts are
allen head bolts. Use a 3/8" socket for the allen head bolts - your
local NAPA store will have the socket. Be real careful to visualize this
clutch assembly and how the little springs go back in place. Some may
have popped out when the flywheel came off - another reason to have some
towels to catch parts when the flywheel pops off.
If you decide to proceed, I will be available by telephone
to walk you through it. I'm in Oregon - Pacific time.
503.588.3973.
Good luck,
Rey
