New Member, New Bike, Lots of parts on their way!

[Rimfirekyle]

Hello everyone. My name is Kyle and I was just given a 1976 Honda XR75. Engine case says XR75E (if that matter) Well the bike ran....very....very poorly. It had no power and smoked. Started disassembling bike and got to the motor. Found a ring busted,a tone of carbon, and one twig on top of the piston. I wanted to make this bike nice and if i was going to tear it down to fix it, I was going to do it right. So, I ordered a ton of parts which will be here monday or tuesday and I am excited.

I started tearing down the engine and got the top end off no problem. But, how do I get the flywheel off?

I love the site and there is a lot of good info here, I hope to be here a while.

[PlanetMinis.com]

[vintagemx]

Nice project. I bought a "running" early XR75 (cobbed together from '73 - '76 parts) for my oldest boy. Previous owner claimed he rebuilt the engine, but that it had "old gas". It didn't take me long to realize his mechanical skills are seriously lacking. Old gas wasn't the problem, too much gas was. Ended up rebuilding the carburetor, which got the bike running, but the spark was very weak and would still foul plugs. Changed both the stator and ignition coils and now it has good spark. The engine burns oil, so the top end needs to come down and the bottom end has a leak. That said my son still rides the bike and has raced it a couple times. I'll probably end up rebuilding it back to stock someday.

[Stubo]

You will need a flywheel puller, you will also need a special tool to remove what Honda calls the oil filter if you paln on splitting the cases or doing any type of clutch work,
I made the tool but you might be able to still buy it. I will get a photo for you as soon as i can

[Rimfirekyle]

thank you so much..... i ordered the flywheel puller..... apic of the other tool will be great!

[dirtbkr188]

A pic of the tool is HERE, and the nut you use it on is part #16, shown HERE.

[Rimfirekyle]

ordered the tool.... thank you so much.... That site has all the blown up diagrams which is awesome. Is there a site out there that has them in a printer friendly format?

[dirtbkr188]

Yes, go back to that site, click on Large Image right under the diagram, when it opens, right-click on it, click on Print Picture.

[Rimfirekyle]

Ok well, I have good news and bad news.......
All my parts are here and they look awesome....
Tank, frame, swingarm, and various pieces are blasted and headed to paint.

bad news. Threads on flywheel are goobered and I cant get it off.... Any Ideas?

[vintagemx]

You do realize the threads in the flywheel (for the puller) are left-hand threads.

Lefty-tighty, righty-loosey

[Rimfirekyle]

after about 5 minutes I did....... And I thought " oh yeah, now ill get it" And then realized, nope they really are screwed up. Apparently someone has had this apart before. You can see where they used a crow bar/screwdrive to pry the flywheel off.... ouch

[vintagemx]

Try cleaning the threads with WD40 and a wire brush first. If that doesn't work, plan B... Squirt WD40 around where the flywheel fits onto the crank taper. Heat the flywheel with a propane torch around the crank taper then CAREFULLY pry on the back of the flywheel.

[Rimfirekyle]

Ok, I will try the WD-40 and brush. I have some plastic coated bars for gunsmithing that might work for prying it off of there.

[vintagemx]

Can you get a close-up photo of the threads. Usually just the first thread or two get messed up. Years ago I borrowed a special flywheel thread chaser from a Honda mechanic.

[hobbeekid]

Be careful with the threads on the flywheel they're really fine ind you can easily crossthread when trying to install puller. I also use alittle grease on the inside of puller to keep from galling up or spreading out the end of the crankshaft end also...

[vintagemx]

... use alittle grease on the inside of puller to keep from galling up or spreading out the end of the crankshaft end also...

A dab of anti-seize or Texaco "ThreadTex" works even better.

[Rimfirekyle]

Well i took to "Off road connection" A local repair shop. He is going to try. Might pick it up tonight if he gets it off.... I want to finish rebuilding the motor this weekend if I can.

[Rimfirekyle]

Ok, so it has been a while since I posted so I thought I would update. Picking up frame, fenders, and tank from my paint guy this evening. I will post picks this evening. Im pumped! Ive been busy and still have not got the flywheel off of it. The guy at the repair shop couldnt get a puller to thread into it .I got the puller to thread in about 2 threads and am going to try to pull it off tonight. I would love to have a thread chaser and mentioned above but cannot find one locally.

PICS TO FOLLOW THIS EVENING

[Rimfirekyle]

Also I want to replace my fork seals tonight..... I couldnt find a post explaining how...... any one know of a page describing this process???

[vintagemx]

I'd highly recommend getting a Honda XR75 service manual. Accept no substitutes. Re-mx sells copies, but the photos aren't very good. Look for an original on Amazon or flea-bay.

Try talking to a Honda mechanic about chasing the threads. The one I borrowed looked like it had been made from a flywheel puller, with 4 grooves cut vertically the length of the threads.

[bluebanshee]

I've never used the thread in pullers and have never had one that I couldn't get off. A regular puller, some heat and some light taps have always popped them off for me.