HOW TO MAKE A 94 ATK 406 FLY WHEEL PULLER

[Sandblaster]

I have a 1994 ATK 406 that needs a lot of work.
I started taking the bike completely apart.
When I got to the point where I needed to pull the fly wheel off I realized that I do not have the correct puller.
Here is a pic of the flywheel on the bike.
It uses a very non standard thread.

So, I went to my parts catalog to order one and no such puller was available.
So I contacted ATK, gave them all my info and ordered a puller.
They were not even sure they could get one.
It's been a few months now and I am tired of waiting so I decided to make my own
The first step was measuring the thread pitch and diameter that I would need and ordering the correct size tap.
Then I went to a local machine shop and gave them a print of what I wanted.

Of course the print I gave them has the measurements
After I get the puller back I will post some pics and let you know how it works.

[Sandblaster]

Well, I think I know why ATK stopped carrying a puller for these fly wheels.
The threads are very fine.
In fact, these are the finest threads we have ever seen for a fly wheel of this design.
My guess is that people strip the threads because they are in very poor condition and very fine.
I will need to chase the threads on the flywheel with a die.
So, I ordered a die for it but it will be a few weeks before it gets here.
I'll let you know what our progress is.

[Sandblaster]

Here it goes.....

[Sandblaster]

FAILURE!!!!!!
I pulled the threads right out of the tool and the fly wheel.
I guess I should have had the threads hardened.....
M29 X 1.0 threads are very fine.
Then again the threads on the flywheel were in very bad condition.
If you try this I highly recommend that you have the threads hardened.
In all fairness the fly wheel is really stuck.
I had to put a lot of torque on it to pull the threads out.
If you try this and have better success, let us know what you did.
Thanks!
SB