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Discussion Starter · #1 ·
I'm tearing down a spare engine for a 2000 Monster 900S. While the manuals call for dozens of special tools, I've gotten by with just 2 (alternator cover and clutch basket). I've gotten the engine 90% apart. But now I'm stuck.

I'm trying to remove the primary drive gear from the crankshaft. This is the one on the RH side of the engine, just behind the oil pump. I got the nut off, and according to the shop manual, I'm supposed to use a puller to get the gear off the shaft. I've resorted to bracing the gear from rotating as well as moving in toward the casing. NOTHING is moving this gear off of the shaft. I've tried rubber mallets and hammers on 2x4s. This gear is just not coming off.

Looking at the exploded parts view, it's not threaded. It's just sitting there. And it won't move. I've also applied heat, thinking that someone may have put loctite on it before.

What am I doing wrong? This is the last real problem before I can start selling the parts. HELP! Why doesn't this gear come off?

Thanks.
 

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Discussion Starter · #2 ·
Quick update...

I bought a standard gear puller for $30. It's a 5-ton puller with 3 claws. It fits nicely over the gear in question. The only problem is, the gear just isn't coming off. If I didn't know any better, I'd say there's a clip or screw holding it in place, but the shop manual shows nothing and I can't see anything when I thoroughly inspect it. I think I may just have to take it to the dealer when I have my bike serviced. This gear isn't moving for anything.
 

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Hi Idlehands,
I removed the same gear off of my 94 M900 and it was a real bitch. The shaft that the gear fits on is tapered and the gear has locked onto the shaft. There is also a keyway to keep it from rotating (like it ever will!). Here is what I did. I got the biggest puller I could fit and used an impact wrench. I put penetrant on the outside of the gear and used the impact wrench and tensioned the heck out of the puller. I then just let it sit overnight. I did this for about 3 days and it finally let go. Good luck. Also, be very careful to be out of the way of the gear. When mine finally let go it shot back and put a hole in the sheet rock in my garage wall!

Mike
 

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Discussion Starter · #4 ·
Wow. Thanks for the advice. Yeah, I was convinced that the gear puller was going to destruct and take my arm or leg with it, considering the tension I had on it. I backed it off while rummaging around for another option, but put it back on to moderate tension.

I've basically done the same thing, although not with as much tension. It's sitting in the garage right now, and I won't get to it until next weekend. I put some penetrating oil on it, so now I'll just sit and wait. Maybe I'll crank it a litter harder tomorrow.

But it's good to know that its not just me. Thanks for the info!
 

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Heat the gear, and stuff dry ice in the crank? :D
 

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Discussion Starter · #6 ·
Geesh. I give up. For the past two weeks I've had gear pullers on the gear with radiator clamps around the pullers to make sure they don't pop off. I've used quite a bit of PB-Blast. I've heated the gear a number of times. I've even used a hammer and block of wood on the puller while the gear was heated. This gear just isn't coming off.

I have to take the bike into the shop to have them figure out why it's popping and coughing, and when I do, I'll just take the old engine assembly in and have them take it off. I swear it's welded on.
 

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Discussion Starter · #7 ·
I've got a final update on this one. I tried for about 2 months to get the gear off using all types of things like pressure, heat, cold, and penetrating oil. I just couldn't get it off. So I took it to a local garage.

The guy at the garage tried all the normal things, too. His torch was hotter and he heated the gear up more than I could with mine. But that still didn't do it. He finally put it into his huge machine press and got it off after applying 6 tons of pressure to it. No wonder I couldn't get it off at home.

It's a tapered shaft, but it still shouldn't take that much force. At least I have it off now. Next time I'll just take it straight to a Ducati dealer and let them deal with it.
 
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