Wilsons Sandbox

I am having a hell of a time getting the lower race out of my steering stem. The Clymer manual stated "hit it with an aluminum drift" but there is no way to get a bite on the race. The top one I knocked out no problem, but the lower one has a shoulder above it that precludes getting a bite on it with a chisel / punch / screwdriver. The Kawi service manual shows a special tool, I went to my local auto parts and rented a 2 and 3 jaw puller with a slide hammer, but the damn jaws are too fat to get in between the race and the shoulder of the housing it rests in. At this point, I'm looking to beg steal or borrow the Kawi tool, or I'm going to have to try some wacky stuff with a bag of ice and a heat gun. Help! Thanks CA Stu A13 :-(

You have access to an electric welder?  I'd run two beads 180 from each other on the race and then smack it with a hammer.     Works for me.   [b]From:[/b] s2mumford@... [b]Sent:[/b] Sunday, July 18, 2010 5:45 PM [b]To:[/b] DSN_KLR650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Steering stem lower race removal - problem   I am having a hell of a time getting the lower race out of my steering stem. The Clymer manual stated "hit it with an aluminum drift" but there is no way to get a bite on the race. The top one I knocked out no problem, but the lower one has a shoulder above it that precludes getting a bite on it with a chisel / punch / screwdriver. The Kawi service manual shows a special tool, I went to my local auto parts and rented a 2 and 3 jaw puller with a slide hammer, but the damn jaws are too fat to get in between the race and the shoulder of the housing it rests in. At this point, I'm looking to beg steal or borrow the Kawi tool, or I'm going to have to try some wacky stuff with a bag of ice and a heat gun. Help! Thanks CA Stu A13 :-(

On Sun, 18 Jul 2010 23:45:33 -0000 "SM" writes:

> I am having a hell of a time getting the lower race out of my > steering stem. The Clymer manual stated "hit it with an aluminum > drift" but there is no way to get a bite on the race. > The top one I knocked out no problem, but the lower one has a > shoulder above it that precludes getting a bite on it with a chisel > / punch / screwdriver. > The Kawi service manual shows a special tool, I went to my local > auto parts and rented a 2 and 3 jaw puller with a slide hammer, but > the damn jaws are too fat to get in between the race and the > shoulder of the housing it rests in. > At this point, I'm looking to beg steal or borrow the Kawi tool, or > I'm going to have to try some wacky stuff with a bag of ice and a > heat gun. > Help! > > Thanks > CA Stu A13 :-(

<><><><><><> <><><><><><> CA Stu, A couple of methods that might be suitable for you could be: - Using a wire feed welder you could weld a bead on the inside of the outer race. When the race cools a little (about 30-45 seconds) you can probably remove the race with gloved fingers. If you have the new race ready (frozen) you can probably install it immediately while the steering head is still hot. - You could also place a large flat washer inside the outer race and weld it to the race. Then knock the race out with a drift and a hammer. But if you weld the flat washer in place the race will probably just about fall out pretty much like in the first suggestion. - Take a dremel tool with a cut off wheel (an air powered die grinder might be quicker) and make two relief cuts in the steering head above the outer race so you can get purchase with a drift. - Try a puller like that used for BMW airhead motorcycles. The lower bearing on the KLR is the same as both bearings in the older airheads. I think you could find one at cycleworks. You might need to google search it and it might work well if you include Ed Korn in the search. He owned Cycleworks and invented a lot of good tools for airhead maintenance. One of the neat results from the welding and shrinking methods above is you can then use the shrunk race as a driver when installing the new race and it won't get stuck in the steering head. Good luck with your race removal. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Get Free Email with Video Mail & Video Chat! http://www.juno.com/freeemail?refcd=JUTAGOUT1FREM0210

Jeff, Fred, and others thanks for the suggestions, looks like I will grab a mig welder from work tomorrow and I'll be back in business. The frustration of going after it with a slide hammer and both a 2 and 3 jaw puller gave me a headache (100+ degree weather didn't help), and the Clymer manual has a flaw in it. Thanks CA Stu --- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote: > > - Using a wire feed welder you could weld a bead on the inside of the > outer race. When the race cools a little (about 30-45 seconds) you can > probably remove the race with gloved fingers. If you have the new race > ready (frozen) you can probably install it immediately while the steering > head is still hot.