How to Remove Dirt Bike Flywheel Without Puller?

remove dirt bike flywheel with out puller

Do you want to remove a dirt bike flywheel but don’t have a puller? Removing the flywheel on a dirt bike is a daunting task. It’s crucial for maintenance or repairs to draw a dirt bike flywheel. While flywheel pullers are designed for this specific purpose, alternative methods can be employed to remove the flywheel without a puller. 

So, it’s possible without a puller but requires inventiveness and careful tools to ensure the flywheel is safely and effectively detached. This article will explore creative approaches for removing a dirt bike flywheel when a puller isn’t readily available. We’ll also provide some safety tips to help you avoid any accidents.

Let’s dive in for more information!

What is a Dirt Bike Flywheel?

A dirt bike flywheel is a circular or ring-like heavy metal component on the crankshaft behind the engine’s primary cover. It helps to run the bike’s engine smoothly. When the engine starts, the flywheel stores its energy in its rotation and then releases it as needed to keep it running smoothly. It helps out the power delivery and prevents the engine from stalling.

So a flywheel serves essential functions such as:

  • Storing rotational energy
  • Aiding ignition timing
  • Balancing engine components
  • Accommodating a starter mechanism.

Flywheel removal is necessary to access the internal engine parts of a dirt bike. At the same time, specialized tools like pullers are commonly used, and alternative methods can be applied cautiously when a puller is unavailable.

dirt bike flywheel

Why Remove a Dirt Bike Flywheel Without Puller?

Detaching a dirt bike flywheel without a puller can be beneficial for saving your time and money. Plus, it might become necessary due to various reasons and circumstances. While using a puller is the recommended method for safety and precision, that is a simple process, and anyone can do it. 

However, the pullers may be expensive for some, and if you don’t have one, you may have to go out and get one. Moreover, you’ll need to rent or borrow an impact wrench to pull the flywheel bolts.

If you have a few essential tools for removing a flywheel, you can do it without a puller in 15-20 minute it’ll be the best chance to learn about your dirt bike and how it works. In short, save money and time by removing your dirt bike flywheel without a puller.

Below are some situations where riders, mechanics, or you might remove a flywheel without a puller. These could include:

  • Emergency Repairs: If stranded in a remote location without access to specialized tools, removing the flywheel without a puller could be a temporary solution to address immediate issues.
  • Lack of Tools: You may need a suitable puller. While using the right tools for the job is advisable, creative solutions might be considered when pullers are unavailable.
  • Time Constraints: If you need a quick repair or maintenance task and can’t wait to acquire a puller, alternative methods expedite the process.
  • Resourcefulness: Some enthusiasts enjoy finding innovative ways to solve mechanical challenges. Removing a flywheel without a puller can test skills and resourcefulness.
  • Limited Access: On occasions when you can’t easily access a flywheel’s mounting area due to design constraints, you might need to explore unconventional removal methods.

It’s important to note that removing a flywheel without a puller can be risky. The flywheel is a delicate component, and improper removal methods could cause damage to the flywheel, the crankshaft, or other engine parts. Using the appropriate tools and techniques recommended by the manufacturer or a mechanic is the safest way.

Tools Required to Remove Flywheel Without Puller

To remove a dirt bike flywheel without a puller, consider using the following:

  • Rubber mallet
  • Wooden block and hammer
  • Heat source (cautiously)
  • Penetrating oil
  • Hammer and screwdriver
  • Pry bar or lever
  • A socket wrench
  • A C-clamp
  • Gloves
tools required to remove flywheel without puller

Step-by-Step Guide on How to Remove Dirt Bike Flywheel Without Puller

Here’s a step-by-step guide on how to remove a dirt bike flywheel without using a puller:

1. Disconnect Ignition Components

Firstly, disconnect the spark plug wire and the negative battery cable to prevent accidental engine firing during removal.  

2. Cool Down Bikes’ Engine

If you’ve been riding till now, your engine can be hot. Removing the flywheel without a puller with a hot-engine bike can be difficult. So, please turn it off and let it sit idle for at least 30 minutes to cool down your engine.

3. Loosen the Flywheel Nut

The flywheel nut is located on the back of the flywheel that secures the flywheel onto the crankshaft taper. It’ll be tightened with a large socket wrench. Use a breaker bar, wrench, socket, or spanner to loosen the nut. Moreover, applying penetrating oil would be best if the nut is stubborn due to rust or corrosion. And continue turning the nut until it’s loose enough to remove by hand.

loosing flywheel nut

4. Remove the Flywheel

When the engine is cooled down, and the flywheel nut is loosened, you can easily remove the flywheel without any puller. Place the C-clamp on the flywheel and tighten it until the flywheel is loose. 

Now remove the cap on the end of the crankshaft first—generally, 3 or 4 bolts holding the flywheel in its place. There may be two small holes in the flywheel when the cap is removed. The holes are located near the edge of the flywheel.

Use a screwdriver or punch to drive two screws into these holes. Be cautious so that it’ll not damage the threads on the crankshaft. Now you can pull the flywheel off the end of the crankshaft.

5. Inspect the Flywheel

Once the flywheel is removed, it’s time to inspect the flywheel, crankshaft, and surrounding components for any damage. If you’ve observed any cracks or signs of damage in the flywheel, it’ll need to be replaced. But if the flywheel is good, you should clean it and use it again.

You can clean the flywheel using a brush or sandpaper to remove rust or debris on the surface.

inspect flywheel

6. Inspect the Clutch Assembly

After removing the flywheel:

  • Inspect the clutch components for wear, damage, and proper function.
  • Check clutch plates, springs, pressure plates, and clutch basket for signs of wear, flatness, or oil contamination.
  • Replace worn parts and ensure smooth operation before reassembly.

It helps maintain an efficient clutch system for optimal dirt bike performance.

7. Reinstall the Flywheel

That’s your flywheel tidied; you can reinstall it on the crankshaft again. Align the holes in the flywheel with those in the crankshaft. 

Tighten the nut or screws until they are snug. Be careful not to overtighten them, as it can damage the threads on the crankshaft. Once the flywheel is secure, you can install the clutch assembly and reassemble the engine.

That’s it! You’ve now learned to remove the dirt bike flywheel without a puller. This method is quick and easy and doesn’t require any special tools. You can save time and money by doing it with patience. Thanks for reading!


A heavier flywheel will provide smoother power delivery and more torque, helping to climb hills and ride in rough terrain. However, a heavier flywheel will make the engine harder to start and accelerate.

Consider Some Safety Precautions

There are things to keep in mind in removing a flywheel:

  1. Wear safety gear: Gloves and eye protection.
  2. Allow the engine to cool down.
  3. Secure the bike on a stable surface.
  4. Disconnect the spark plug.
  5. Use gradual force, and avoid sudden movements.
  6. Choose the correct tools for each step.
  7. Keep hands away from moving parts.
  8. Prevent engine movement.
  9. Work in a well-lit area.
  10. Follow manufacturer guidelines.
  11. Regularly inspect components for damage.
  12. If you need more clarification, seek professional help.

How to Remove a Dirt Bike Flywheel without Tools?

There are a few ways to remove a dirt bike flywheel without using any tools. One method is to unscrew the bolts by holding them in place. At the same time, the other way is to use a socket to loosen the bolts and nuts. 

When the flywheel nuts are loosened, you can remove the flywheel by hand. Remember that you may need to use force to get it off. You can access and inspect the clutch for damage with the flywheel removed.

How to Make a Flywheel Puller?

You’ll need a few tools and supplies to make a flywheel puller, such as:

  •  A length of thick rope or twine.
  •  Two strong magnets.
  •  A piece of metal or wood to serve as a handle.

After gathering the required materials, you can make your flywheel puller at home.

Foremost, tie up the rope or yarn around the magnets to securely attach them. Second, connect the other end of the string or twine around the metal or wood piece. In the end, clasp onto the handle and use it to drag the flywheel off the engine.

With some practice, you can easily remove flywheels using this simple tool and method.

How Do You Loosen a Dirt Bike Flywheel Nut?

The flywheel is one of the most essential parts of a dirt bike’s engine and one of the most delicate components. 

Loosening a dirt bike flywheel nut is a precise process that requires attention to detail and safety. Begin by ensuring you’re wearing proper safety gear and that the engine has cooled down. If necessary, remove any cover obstructing access to the flywheel area. Place a cloth or wooden block between the fins and casing to prevent the flywheel from rotating. 

Choose the correct tool that matches the nut size, such as a socket or wrench. Turn the tool counterclockwise while applying steady and controlled pressure. If the nut is resistant due to rust, a small amount of penetrating oil can help. 

Gradually, the nut will begin to loosen. Monitor its progress and continue turning until it can be removed by hand. After relaxing, inspect the nut and surrounding components for damage before proceeding with maintenance or repairs. This process is a safe and effective approach to loosening the flywheel nut on a dirt bike.


In dirt bike maintenance, mastering the art of removing a flywheel without the aid of a traditional puller stands as a testament to resourcefulness. As we guide this unconventional journey, we’ve delved into a realm where ingenuity meets necessity, crafting solutions that dance on the edge of creativity. 

By weaving together essential tools and strategic approaches, we’ve unveiled a path less traveled—a method both daring and calculated. Remember, while this venture requires a careful hand and keen observation, it reveals a new layer of mechanical prowess, showcasing that even without standard tools, the heartbeat of innovation continues to pulse within the realm of dirt bike enthusiasts.

Flywheel pullers can be costly and hard to find. In this article, we’ve shown you how to remove the dirt bike flywheel without a puller. Have you tried this method yourself? Let us know in the comments below!


What Is a Flywheel Puller Used For?

A flywheel puller is a specialized tool to safely remove a flywheel from an engine’s crankshaft. It prevents damage and is crucial for maintenance, repairs, and component replacement tasks. Providing controlled and efficient force ensures smooth and accurate flywheel removal.

What Is a Flywheel Holder?

A flywheel holder is a tool used to immobilize or secure the flywheel of an engine in place while performing maintenance, repairs, or tasks that require applying force to other parts of the bike. It prevents the flywheel from rotating, allowing you to work on components like clutch assemblies, crankshafts, or other related parts without risking accidental movement. This tool ensures safer and more precise work, especially when dealing with tight bolts, nuts, or components that could otherwise rotate freely.

How can you remove a dirt bike flywheel without a tool?

Removing a dirt bike flywheel without a tool can be challenging, but you might attempt this by gradually tapping the flywheel’s edges using a rubber mallet or hammer while holding the bike steady. The vibrations created can help loosen the flywheel. However, proper tools or a flywheel puller are recommended for safety and effectiveness.

Can we run without a flywheel?

Running a dirt bike without a flywheel is not advisable. The flywheel serves essential functions such as energy storage, ignition timing, and engine balance. Removing the flywheel can lead to erratic engine performance, potential damage, and unsafe riding conditions. Always keep the flywheel in place for proper engine operation.

How to remove the 2-stroke flywheel?

To remove a 2-stroke flywheel:

  1. Ensure safety gear and engine cool-down.
  2. Remove any covers obstructing access.
  3. Use a flywheel puller tool for controlled removal.
  4. Thread the puller into the flywheel.
  5. Gradually tighten the puller to create pressure.
  6. The flywheel will loosen; remove it carefully.

Using a flywheel puller ensures safe and effective removal without damaging components.

How to remove the flywheel nut without an impact wrench?

For removing a flywheel nut without an impact wrench, you may:

  1. Use a proper-sized wrench or socket.
  2. Secure the flywheel with cloth or block.
  3. Apply gradual counterclockwise force.
  4. Use a cheater bar for extra leverage if needed.
  5. Ensure steady pressure to loosen the nut.
  6. Remove the nut by hand once loose.

Take care not to damage the nut or components during removal.

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