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nearfreezing

best way to pull flywheel on 2002?

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Seems the stator after 24k has finally shed the ghost. The charging voltage at idle drops from 13.1V to the low 12s with either the high beams or radiator on. Last I checked a year or so ago the idle voltage was 14.2V. Since this is a 2002, the flywheel must be replaced with the 2003+ 6th gen flywheel and the updated 2003+ stator, along with the stator-to-cover screws and cover gastket. This is sold as a kit for $287 on partzilla but is on backorder without an eta. I decided to buy the stator, gasket, and screws separately for $250 from partzilla plus a used 2009 flywheel for $21 off e-bay for a total of $271.  

 

I'm trying to figure out how to remove the flywheel. I will use a strap wrench to hold the flywheel still while breaking the bolt. But then what's the best way to pull the flywheel? The flywheel puller bolts available on-line are 20mm x 1.5mm right-hand threaded but all the sites say these are for the 5th gen. None lists a flywheel puller for the 6th gen.  Anybody know the specs to use? Alternately, has anybody used a three-arm puller? If so, which one?

 

Looking forward to getting back on the road, thanks for any advice!

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Interested if you could post up any tips from the process.. I have a 2002 as well at ~40k miles, I haven't opened the stator in the time I've owned it, so unkown status.  I wasn't sure what exactly is required to change to the 'updated' (03+) stator, but at some point I'll have to get in there

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3 hours ago, nearfreezing said:

Since this is a 2002, the flywheel must be replaced with the 2003+ 6th gen flywheel and the updated 2003+ stator

Why?  This is me replacing the stator on my 2002 with a couple of hand wrenches in the parking lot of a hotel in South Dakota last summer.  

 

image.png.5db6d4120798d4545ffedb5236b27063.png

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I've decided on the OEM stator since experiences with aftermarket stators varies. The OEM stator lasts at least ~20,000 miles or so.

 

The OEM 2002 stator is no longer available as it is superseded by the 2003-2009 stator, starting with a product update campaign when it was found that the 2002 charging system was undersized and would discharge the battery when both the high beams and radiator were running. The 2003-2009 stator is larger in diameter than the inner diameter of the 2002 flywheel, and so the flywheel must also be replaced with the updated 2003-2009 flywheel. 

 

Here's a link to the replacement process:

 

After looking into it a bit more closely, it seems the flywheel puller is essentially a 20mm x 1.5 right-handed threaded bolt, and I've purchased the Motion Pro Flywheel Puller M20x1.5 r.h. external thread (Motion Pro p/n 08-0086). Hopefully this works. Honda also makes two forms of this tool. One is a 4-arm cross-shape with different threads at each arm (Honda p/n 07733-0020001, MSRP ~$40) -- this does not seem to be available in the US but can be purchased from Japan. The other, which is available in the US, is a bolt attached to a T-handle (Honda p/n 07933-3950000 Puller Dynamo, ~$21) -- this seems to be potentially cumbersome or dangerous since it will require hammering on the skinny T-handle bars.

 

The flywheel holder is essentially a strap wrench with a metal band (Honda p/n 07725-004000) that has an MSRP of $297. 

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I wish you well on your endeavor.

I'm feeling lucky.    Cageless and I must have got the last factory 2002 spec stators left in the world.   I'm not sure I would go through all this to upgrade to a physically larger stator and flywheel if it were me.  I would just rewind the OEM and ride on.   I got 55,000 miles out of mine and it only gave up the ghost on a desperately hot ride across the wastelands of Nebraska.

 

Cageless' stator (L), my stator (R)

07-20180712_164723.thumb.JPG.44bb464c13a9368b007a878d506469ee.JPG
 

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3 hours ago, Lee 2002 said:

I got 55,000 miles out of mine and it only gave up the ghost on a desperately hot ride across the wastelands of Nebraska.

Lee2002 has the one of the most-photographed toasty stators in existence:

 IMG_4217.thumb.jpg.d3ecab9d3aa263e55636aab880d4661c.jpg

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4 hours ago, Lee 2002 said:

I wish you well on your endeavor.

I'm feeling lucky.    Cageless and I must have got the last factory 2002 spec stators left in the world.   I'm not sure I would go through all this to upgrade to a physically larger stator and flywheel if it were me.  I would just rewind the OEM and ride on.   I got 55,000 miles out of mine and it only gave up the ghost on a desperately hot ride across the wastelands of Nebraska.

 

Cageless' stator (L), my stator (R)

07-20180712_164723.thumb.JPG.44bb464c13a9368b007a878d506469ee.JPG
 

Great picture that. Just for info, notice the burnt poles are matched, and the three or four poles that look good are matched, the good poles are at the lowest point and seem to get a good oil flow over them displacing the heat. It's interesting Honda have addressed this problem on the 8gen by installing an oil sprayer for the stator.

Cheers.

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On 6/2/2019 at 10:54 PM, huskysooner said:

Lee2002 has the one of the most-photographed toasty stators in existence:

 

It is hard not to when you have a crowd like this watching your every move.....  You would have thought I birthed a baby the way the crowd gathered when that thing was extracted.

 

Great observations on Grum's part.   There was a reason I clocked those stators the way I did.   There is a lot of information about the 6th gen stator situation in that photo... and every 6th gen roasted stator photo I've ever seen.

36946091_10155374926480426_1271285670798688256_n.jpg

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