I am trying to pull off my flywheel, but can't seem to get it loose. Is there some special tool to get it off? I don't have my manual handy, left it at work, so I can't look it up. I tried a pulley puller, no luck.

 

You need the flywheel puller.

 

Thanks West.....I think I will first try a M30 X 1.5 bolt, maybe it will do the trick. If not, I guess I will find and purchase the darn tool from Kawasaki.

 

I think I will first try a M30 X 1.5 bolt, maybe it will do the trick
That should work!
Way back, I had to pull the flywheel on my 85 KLR and that's the way I ended up doing it. Had to look all over town for that odd-ball size. Finally found one at a specialty fastener place, and the guy just gave it to me. It was an expensive bolt, $10 or so. I think the guy was used to selling large quantities to large companies, and didn't feel like screwing the little guy. Probably didn't cost him much at all, but it made my day.
Good luck ddt

 

Thanks. I think I read somewhere you could use the rear axle to do this, will try that and see if it's true. (Going outside with rear axle in hand)....

 

(Coming back in with rear axle in hand) It fits perfect!! No need for Kawasaki special purpose tool, they already gave you one with the bike....
Now all I need is a good strap wrench to hold the flywheel while screwing in the rear axle with an impact wrench. Back to the shop....

 

Sounds like a great fix!! Psot a photo or two if you have time!!

 

Rear axle great tip! Thanks for sharing, now I just have to remember it.

 

That should be stickied somewhere, or put in one of the maintenance tips page.... or something... Good trick

 

Well two years later I need this exact info, and I don't remember the freaking tip!!!!! I spent all morning looking up flywheel pullers , not finding the right ones and not wanting to pay the money and wait for shipping etc etc. Started looking up metric bolts to use as a puller. $25 for one M30x1.5 bolt! and you have to special order that. Finally do a search on KF to see if anyone else has encountered this problem and voila, I find this thread with the answer, and a few other threads with people unsuccessfully looking for flywheel puller help. moral of the story is always search on KF first.

The rear axle works like a charm to pull the flywheel. ( on my 07 klx at least) I had already figured out that I could use my vise grip locking chain wrench for a flywheel holder. Now with that holding the flywheel,a bit of heat from the heat gun, the rear axle threaded in to push on the crankshaft, and a few whacks with my had on the ratchet it popped loose.
Ta-effing-da! Thanks DDT, I think he sold his klx and moved on to something bigger over there in Japan, but his valuable little tidbit of information, saved me a little money and most of all a lot of time! Maybe I won't forget the tip this time.
Dan