Removing a KTM flywheel without a puller can be challenging, as using a flywheel puller tool is the recommended method for safe and efficient removal. However, if you don't have access to a flywheel puller, you can try the following alternative methods:
Rubber Mallet Method: This method requires tapping the backside of the flywheel with a rubber mallet or a soft-faced hammer while applying steady pressure to the flywheel shaft. The goal is to create a shock and vibration that may loosen the flywheel. Be cautious not to strike the flywheel excessively hard to avoid causing damage.
Heating Method: Applying heat to the flywheel hub can help expand the metal and loosen any adhesive or corrosion that may be holding it in place. Use a heat gun or a propane torch to heat the flywheel hub evenly. Be careful not to overheat or damage the surrounding components. After heating, quickly attempt to remove the flywheel using steady force.
Alternating Tapping Method: This method involves using a hammer and a metal rod or punch. Place the rod or punch against the flywheel's backside and tap it gently with a hammer. Rotate the flywheel slightly and tap again at a different location. By alternating the tapping around the flywheel, you aim to gradually loosen it. This method requires patience and multiple attempts.
It's important to note that these alternative methods can be risky, as they may cause damage to the flywheel or other components if not executed carefully. It is always recommended to use the appropriate tools and follow the manufacturer's instructions to ensure a safe and successful flywheel removal. If you're unsure or uncomfortable performing the task without a proper flywheel puller, it's best to seek assistance from a professional mechanic or a KTM service center.