I thought I'd resurrect this thread, since I found the idea helpful, and more importantly, it was the only relevant information I found anywhere in regards of removing an output shaft collar, also referred to as an oil seal sleeve or distance collar (Yamaha parts manual).
The output shaft collar on my R1 needs to be trimmed for the same reasons, and I have been struggling for some time to get it removed. I have heard from the vendor of the Hawk adaptor that I should be able to just gently wiggle it off with some pliers, but no dice. I spoke to dealers, searched the R1 forum, searched the net, studied the service and parts manual, but could not find any information. I had tried tapping, after tacking on a bar, some gentle heat, various vice grip, nothing worked. The only thing left was to split the case.
However, I was convinced from studying the manuals and from the above thread, that it should pull off. The split shaft collar option was logical, but possibly expensive, so I devised a homemade solution, that worked. I had an odd, homemade gear puller, that had been laying around forever, and was destined to be chucked many times, when it dawned on me that I could make it work. I had some 4130 tubing that was 34 mm ID (the shaft is 36mm OD), split it and welded on some tabs, then welded the clamp to the puller. Finally, success. Contrary to expectations, if was not corrosion that was the culprit, but the collar is actually pressed on the shaft. Obviously not a part that gets routinely removed, hence no reference in the service manual.
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