Problem removing the rotor assembly - '61 Dream Sport

[primer63]

I've found here in the forum that you can get the rotor assembly off using a rear axle bolt from a Dream. However, that assumes that your rotor threads are in good enough shape to accept said bolt. See pictures attached. The threads on the rotor are smashed flat on the crown of the thread. Apart from the use of the bolt, what are alternate methods of rotor removal that won't damage the crankshaft or rotor in the process?

I am brand new to 305 engine disassembly and want to proceed cautiously. Thanks for any help anyone can provide.

[G-Man]

You may be able to get a three-legged puller in there.

G

[primer63]

You may be able to get a three-legged puller in there.

G

I found a picture of someone else on here that had one attached to their rotor. A question. Can I position the puller jaws anywhere that I can get a purchase on the rotor?

[bamacl]

If it's the end threads you can use a "bottom tap" to repair them.

[Mike Mullins]

try a 16 mm. x 1.5 mm thread pitch bolt. On my Super Hawk, there was no bolt on the bike that would fit that hole. I used the bolt, threaded it down till it contacted the shaft solidly, gave it a sharp rap with a hammer, and it came off easily. Might be hard to find that size bolt at the corner hardware, but a supply place should have it.

[primer63]

try a 16 mm. x 1.5 mm thread pitch bolt. On my Super Hawk, there was no bolt on the bike that would fit that hole. I used the bolt, threaded it down till it contacted the shaft solidly, gave it a sharp rap with a hammer, and it came off easily. Might be hard to find that size bolt at the corner hardware, but a supply place should have it.

Mike,
See my initial entry. I have a rear axle bolt of the appropriate size and pitch. However, the prior owner flattened all the threads, likely with an SAE bolt that seemed to work. My axle bolt would not thread into the rotor and seat on the end of the crank. I had to try something else.

We got the rotor off by seating a 9mm socket against the crankshaft end, capping that off with a piece of wood (imagine a propeller configuration). Then attaching two c-clamps hooked behind the back edge of the rotor and to each end of the "propeller." Slowly tightened each clamp a little at a time until the rotor popped off. If anyone needs a picture of that makeshift rig, I'll post one.

[Mike Mullins]

I Love that !!! (You are my kind of mechanic )
Mike. (Aka. Mikeyrx)