Hi KDXers,
I have a a 1980 KDX250 that has seen better days. The flywheel does not appear to be the conventional type and looks like it needs a special tool to properly pulley on it to get it off. I got the bolt out but can’t pull the flywheel off. No inner threads and the push bolt on :my universal puller is not pushing against the crank it seems but against the flywheel itself. The area that it appears to need to push against is pretty small..thread the bolt in a little and push against that? It’s quite rusty. I have been hitting it with PB Blaster and a torch..help!
Thanks
Right Flywheel puller for a 1980 KDX250
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billie_morini
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Re: Right Flywheel puller for a 1980 KDX250
MX360guy,
please upload a photo of your flywheel and your universal puller.. There are KX 250-specific flywheels at Rocky Mtn ATV, Amazon, eBay, etc.
please upload a photo of your flywheel and your universal puller.. There are KX 250-specific flywheels at Rocky Mtn ATV, Amazon, eBay, etc.
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KDXGarage
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Re: Right Flywheel puller for a 1980 KDX250
If it is like the 1986 - 1988 air cooled KDX200's, it takes a puller that uses 6 mm bolts that BARELY thread into the flywheel and a small frame. It is not the 1989 and newer style puller that is 27 mm x 1 mm left hand threads.
Here is an example.
https://www.dssalesusa.net/store/p36/Ma ... uller.html
I once pulled my 1987 flywheel with a steering wheel puller. It was like a "Y". I used some 6 mm bolts and washers to get an even grip on it.
Here is an example.
https://www.dssalesusa.net/store/p36/Ma ... uller.html
I once pulled my 1987 flywheel with a steering wheel puller. It was like a "Y". I used some 6 mm bolts and washers to get an even grip on it.
Thank you for participating on kdxrider.net. 
To post pictures from a device: viewtopic.php?f=88&t=24128
To post pictures from a device: viewtopic.php?f=88&t=24128
Re: Right Flywheel puller for a 1980 KDX250
Hi KDX team,
Been away for a awhile. I was able to get the flywheel off using a "Y" puller with a steel standoff to push against the end of the crank shaft..
It partially crushed the standoff...dang that thing was on there. Thanks for the tool suggestion. The mounting screws for the stator were very rusted. I got 2 of the 3 out. The last one is going to be tough. I don't want to break it off if possible. Patients got the 1st two out.
If I get the stator off successfully, I will get a a VAPE ignition. The next big hurtle will be finding a decent exhaust pipe. This one is rusted out at the header. The ODO reads only 1,300 miles, the crank bearing feel good,. Just replace all of the seals and gaskets...The PO showed compression at 125 with rusted pipe holes so there is hope. Still uncertain about the coated cylinder vs a sleeve. A guy who posted a YouTube video of an '80 KDX250 said his bike had a sleeved cylinder...I won't know until I pull it off. Gas tank is good, seat will need foam and cover. Need new rear shocks. Fronts are in good shape. No rust; the fork boots saved them. Just need seals and cleanup I hope. The air box is there but will need all of the internal parts. The throttle and carb is there but not in good shape. I would like to keep it but I am not sure it is salvageable. The headlight is there but needs to be replaced, plastics; need all. Wheels need some love but seem straight. Original Goodyear Eagle on front but a Yokohama on the back. Both need to be replaced. Looked like it was crashed a lot in its short life judging by the bent foot pegs and levers.
Been away for a awhile. I was able to get the flywheel off using a "Y" puller with a steel standoff to push against the end of the crank shaft..
It partially crushed the standoff...dang that thing was on there. Thanks for the tool suggestion. The mounting screws for the stator were very rusted. I got 2 of the 3 out. The last one is going to be tough. I don't want to break it off if possible. Patients got the 1st two out.
If I get the stator off successfully, I will get a a VAPE ignition. The next big hurtle will be finding a decent exhaust pipe. This one is rusted out at the header. The ODO reads only 1,300 miles, the crank bearing feel good,. Just replace all of the seals and gaskets...The PO showed compression at 125 with rusted pipe holes so there is hope. Still uncertain about the coated cylinder vs a sleeve. A guy who posted a YouTube video of an '80 KDX250 said his bike had a sleeved cylinder...I won't know until I pull it off. Gas tank is good, seat will need foam and cover. Need new rear shocks. Fronts are in good shape. No rust; the fork boots saved them. Just need seals and cleanup I hope. The air box is there but will need all of the internal parts. The throttle and carb is there but not in good shape. I would like to keep it but I am not sure it is salvageable. The headlight is there but needs to be replaced, plastics; need all. Wheels need some love but seem straight. Original Goodyear Eagle on front but a Yokohama on the back. Both need to be replaced. Looked like it was crashed a lot in its short life judging by the bent foot pegs and levers.