Replace a flywheel

1.Remove the pull starter
---Remove the pull starter housing (3, 4mm allen head screws)
---Disconnect ignition coil wire



2.Remove the flywheel

---Use a hair dryer to melt the glue on the screw before remove the flywheel mounting bolt (14mm bolt)

---Tap the flywheel with a rubber hammer to loosen it from the crankshaft

---Remove flywheel



3.Mount the new flywheel

---Install new flywheel (line the slot up with the woodruff key on the crankshaft)

*if the woodruff key came out on removal replace it

** torque crank shaft nut to 28nm or 21 ft/lbs



4.Assemble the pull starter

---Re-install ignition coil and plug ignition coil wires back in.

---The distance between flywheel and ignition coil is 0.3~0.5mm or it will result in a failed start

---Re-install the pull start housing slightly pull the pull start handle to align it then install three allen head screws

---Start bike to verify everything works. Go ride!

Video applicable to products:
PAD50-1
PAD50-2
PAD50-3
PAD50-8
PPB50-1P
PPB50-1ES"

[Solvablevoice]

My flywheel touches the pads, is that an issue?

[vrgamez]

my dirtbike pull starter doesn’t start the engine but the pull string works fine so is this the issue?