I had to get rude with one today, much harder to get off than the last one I tried. I had modified an inexpensive 2 jaw puller, but you have to grind it too thin to fit in those little slots. Now I'm trying to visualize what kinda tool might actually work to pull a really stubborn pinion off. What has worked for somebody? Thanks!
Leon, I once got creative with this and I know I'm gonna catch hell from somebody..... Took a steering wheel puller and used the two opposing slots. Took two bolts appox. 3" long that fit through the slots and ground the heads down till they were almost flat, then took one side down till the radius was slightly flattened (experiment till it fits nice behind the pinion). Put them through the puller facing down and use two nuts/washers on the other end looking up at you. Slide the two ground down heads under the pinion slots and screw down the puller. Worked like a charm! But to be quite honest, it's probably easier to buy the right tool. Cheers, Bob
I took an inexpensive two jaw puller and ground down the feet so the just fit. I then used a SS hose clamp around the jaws to keep them from popping off. About ten minutes work and it worked perfectly.
After braking two pullers, my dentist gave me a small saws all for my dremal. I cut as close to the crank as I could and then gave the slot a whack with a chisel. It came right Off! Of course I had to buy a new gear. Not fun at all...........
For the desperate and cheap hacks. Two household butter knifes yep pound them in 180 degrees apart gets it far enough away to grab and pull. You will need to stone the burrs this makes on the gear and crank. You to can be the DPO. Utility knife blades are too hard and thin for this move but will part a tight case. Maybe we can start a list of moves for hacks by (Chisss), short for cold chisel.
norbsa 1960 TR6 1963 Super Rocket 1965 650 Star 1966 441 1968 Thunderbolt 1969 Twinkle 250 1972 Fastback 1974 Roadster 1970 S.S Way too many BSA's not named http://decentcycles.com
I have the puller for Triumph twins (been so long I cant recall if it is pinion or cam gear puller) it cost less than $100 at the time , it didnt work with the BSA though,I've never seen this tool offered for BSA. I seem to recall reading in a manual , maybe factory or haynes?? about prising the gear with a pair of screwdrivrs similar to what Norbsa describes? A bit of propane heat may help , especially if an overzealous type installed the gear, but I have never come across one this determined to stay in situ . The most elaborate I have had to go is pretty much what Mr.Mike describes , but I just used a cheap and expendable harborfreight puller , I'm a cheap sonuvvagun , I'd probably machine and harden a new set of jaws for a cheap puller before spending the money to replace or ruining one of my good pullers .
Two big screwdrivers and a little careful heat is what I ended up doing. But I had intended to be sophisticated this time and do it "right". This gear was much tougher than the last one I did. My pullers mighta worked if I'd heated it first, but I didn;t really want to get the crank hot I guess.
One of the manuals I've seen somewhere has a picture of the two screwdriver method. I used that for years until I made up my own pry bars out of a couple of straight brake spoons. Like Greg and Leon say, a little careful coaxing and you shouldn't need a puller. The only time I've had to use a puller on a BSA pinion was when the crank was butchered out beyond the pinion seat. I suppose one like Alex's would be spiffy to have though! Faster too. But I'm old school.
The crankshaft pinion is sometimes very difficult to extract, and you are likely to deteriorate the crankcase, if you do not have an appropriate tool. If you can weld, it will be quite easy to make this tool, for almost nothing. See the tool I use successfully, which has been manufactured with a little iron dish, two nuts and screws. The notches were machined with a grinder, before welding. To avoid accidental slippage, the tool is tight on the slots, with a locking pliers. It is a great pleasure to work on the A65, with its own tools.