I have been tearing down my original engine to replace the crankcase after a chain mishap destroyed my alternator cover and broke the case. I have the cases in two, only the crank remaining with the primary transmission gear still on. According to the manual, "remove the gear using an extractor," (seems to be a simple gear puller) "and inserting an aluminum pad between the crankshaft and extractor screw." I have done this and using an immense amount of torque it will not budge. Is there some kind of locking device, a key, or something I am missing? I also need to remove the timing control pulleys but do not have the tool, anyone know a way around this? Thanks

Don't know the exact answer to your question,but sometimes tapping on the gear with a soft brass/plastic hammer can help with stubborn gears as it can be quite difficult to apply the force evenly, tapping on the gear can help with the binding that occurs using a "cheap" gear puller. Hope this helps you. Also a press can work much better but you have to pay attention as it can bend and break things if you do not have a lot of experience with such applications of force. Any dissimilar metal over time creates a molecular bond which can be very difficult to overcome,sometimes all it takes is cooling or heating or the rap of a good soft hammer. If you are at your wits end,put the assembly in your freezer for a couple of hours and try it again. It really takes years of experience to safely apply heat in this situation, freezing is a very safe method............good luck

thanks for all the prompt advice on the topic. Did i mention the case is already apart? Well it is and a few light taps freed the crank from the housing, and all the ball bearings on the lower side. After panicking to try to save them all, then removing the remaining, I now have a loose crankshaft rod through the hole with a stubborn gear still attached! I have found a new set of cases, they seem to match nicely with the old set. Any thoughts on simply using one old with one new? I know, I know pretty weak idea, but everything internally is fine, only destroyed the alt cover and the right case when the chain/gear failed. I can provide pics or you can see them on facebook under "dennisofthebeach". Thanks again!

The nut is the main drive gear on the right engine casing. I do need to remove the drive pulley nut at well, so given my poor engineering skills, will require a socket like the one you make (or the ducati tool) to get off. I am kindof in a holding pattern on this, trying to decide if I should use the casing as is and match it to the good left casing. Thanks for the pictures, it definitely helps.

The cases are a matched set, so you should not mix and match. Sorry if this info buggers your plan

You shyould try the puller again but be careful to get it centered. While the gear is under pressure, you can heat the center section of the gear with a propane torch. You do not want to heat any one area too much so just move the flame around the inside and try to keep it off of the the crank bit. All you need to do is creat some swelling (antti will love that expression) of the metal to break the bond that it has with the crank stub. Some taps with a hammer on the puller screw helps too.

You can make the socket in 30 minutes with a grinder. Or, go buy one at the store and take to an auto shop with a 6 pack of cheap beer. They will fall all over themselves to grind it for you! I know I would....

okay, no mixing of the cases. It seemed I would get that response but when you get desperate you are willing to try. I have yet another question before I try the heat. Any suggestions on removal of the oil cooler lines from the case. They will turn about 3/4 of a turn at the case but are totally frozen together at the connecters. Because they are 90 degree elbows, they cannot turn a full 360 degrees to unscrew from the block. This is one item I have not been able to locate a replacement for.

The fastener should revolve around the oil line.
Soak it in WD40 or similar a while, keep one hand on the elbow and try to loosen.

Your just going to have to lean into it to get it loose while you hold the fitting that goes into the case. This is also another spot where you can use some heat on the nut to help it loosen.