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Max Online: 36273 @ 01/23/13 02:34 PM
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#12347992 - 07/19/17 11:57 AM Flywheel Removal?
Jaret Latta Offline
TFF Celebrity

Registered: 01/06/07
Posts: 6855
Loc: Austin, Tx/Nacogdoches, Tx
Ok got a 1999 Johnson 200, swapping parts off the power head to another newer one. We are at a complete standstill and loss of ideas to get flywheel off. Every trick known to man has been used. 3 different pullers, broke multiple grade 8 bolts. Everything short of heating it up which I don't want to do. Anyone else ever come across a stuck flywheel this bad?

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#12348341 - 07/19/17 02:50 PM Re: Flywheel Removal? [Re: Jaret Latta]
TrailHand Offline
Outdoorsman

Registered: 05/18/17
Posts: 91
Mine was stuck pretty bad, but I put my puller on it, tightened it up just past snug to put some umph against it, and soaked it in PB Blaster overnight.

The next day I re-tightened the puller to just past snug (about 1/4 turn or so) and started whacking the center of the puller with a 3 lb sledge. About 10 whacks and it popped loose.

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#12348410 - 07/19/17 03:34 PM Re: Flywheel Removal? [Re: Jaret Latta]
Jaret Latta Offline
TFF Celebrity

Registered: 01/06/07
Posts: 6855
Loc: Austin, Tx/Nacogdoches, Tx
Ya I'm about 2 weeks past all that off and on haha. Welded a grade 10 nut to puller, grade 10 bolt going thru down to motor. 120+ psi impact wrench, something will give....again

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#12349159 - 07/19/17 09:47 PM Re: Flywheel Removal? [Re: Jaret Latta]
TrailHand Offline
Outdoorsman

Registered: 05/18/17
Posts: 91
If you stick with the hammer - on - puller method you should have enough pressure pushing downward that the thing should pop free. You did an overnight soak?

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#12349258 - 07/19/17 10:40 PM Re: Flywheel Removal? [Re: Jaret Latta]
gary purdy Online   content
TFF Guru

Registered: 05/24/03
Posts: 11162
Loc: Littlefield Tx & Lake A. H. US...
Puller tightened with air impact then strike center stud with a hammer has never failed me. Some are harder than others to remove because they have been locktited.
_________________________
The world will not be destroyed by those who do evil, but by those who watch them without doing anything. Remember what He has done and remember that He is not done yet!-- GOD IS GOOD

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#12349447 - 07/20/17 07:33 AM Re: Flywheel Removal? [Re: Jaret Latta]
Jaret Latta Offline
TFF Celebrity

Registered: 01/06/07
Posts: 6855
Loc: Austin, Tx/Nacogdoches, Tx
We're 2 weeks into soaking, breaking puller bolts, 5ft cheater bars, 130psi impact wrenches, Etc. It's insane it's still on. Moving on to heat today and 5lb hammer since power head is useless to us. It's been stripped of components for new power head. Just would like to salvage flywheel assembly

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#12349508 - 07/20/17 08:23 AM Re: Flywheel Removal? [Re: Jaret Latta]
TrailHand Offline
Outdoorsman

Registered: 05/18/17
Posts: 91
Wow, you're really in deep! Man, I'm sorry you're having so much trouble. I've never seen one that didn't respond to the good ol BFH.

Let us know if the heat works. You did take the nut off first, right? roflmao

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#12349662 - 07/20/17 09:53 AM Re: Flywheel Removal? [Re: Jaret Latta]
Muzzlebrake Online   content
Extreme Angler

Registered: 12/26/14
Posts: 1575
Loc: Euless
Get a bigger impact. At least 650 ft/lb and stronger bolts. PB blaster for 24hrs before. If you are going to use heat try to keep it on the flywheel and not on the shaft. Put some grease under the bolt that pushes against the crankshaft so it can turn easier and not gald the metal.
_________________________
From Genesis: "And God promised men that good and obedient wives would be found in all corners of the earth."

Then He made the earth round...and He laughed and laughed and laughed!


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#12349821 - 07/20/17 11:19 AM Re: Flywheel Removal? [Re: Jaret Latta]
Jaret Latta Offline
TFF Celebrity

Registered: 01/06/07
Posts: 6855
Loc: Austin, Tx/Nacogdoches, Tx
Well good news we got it off. Bad news flywheel is toast. It basically fused to the shaft when previous owner dropped a cylinder. We used Thor's Hammer to remove haha. But all the assembly is good. Now I need to track down a flywheel and magnets.....today hopefully. Any ideas where to find one in a pinch? Pretty common motor and that flywheel fits a wide range of engines I believe


Edited by Jaret Latta (07/20/17 11:20 AM)

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#12350775 - 07/20/17 08:56 PM Re: Flywheel Removal? [Re: Jaret Latta]
TrailHand Offline
Outdoorsman

Registered: 05/18/17
Posts: 91
Originally Posted By: Jaret Latta
Well good news we got it off. Bad news flywheel is toast. It basically fused to the shaft when previous owner dropped a cylinder. We used Thor's Hammer to remove haha. But all the assembly is good. Now I need to track down a flywheel and magnets.....today hopefully. Any ideas where to find one in a pinch? Pretty common motor and that flywheel fits a wide range of engines I believe



Glad you got that stubborn buggar off! For the flywheel and magnets, I usually search for the part on boats.net (here's alink to Yamahas) then I either order it from them or find it on Ebay.

http://www.boats.net/parts/search/Yamaha/parts.html

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#12353987 - 07/22/17 11:56 PM Re: Flywheel Removal? [Re: Jaret Latta]
jbobo Online   content
Extreme Angler

Registered: 02/26/13
Posts: 2465
Loc: springtown,tx.
I built a puller with 1" plate and 1" solid bar for leverage. 200 hp 92 rude. Took 4 days. Drilling out holes and bottom tapping with fine threads. Then 8 ft cheater and BFH. Everyone watched from a distance.
I usually order parts from marineengine.com I bet there's one on eBay. 60/40 chance it will be right.


Edited by jbobo (07/23/17 12:04 AM)
_________________________
22 ft. Wellcraft Deep V CC
817-220-2312
Bridgeport/Eagle Mountain/Possum Kingdom/ Lake Texoma
www.bobosguideservice.com
www.bobosthumper.com
www.nekidtackle.com Home of the RonRig!

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#12353993 - 07/23/17 12:10 AM Re: Flywheel Removal? [Re: Jaret Latta]
jbobo Online   content
Extreme Angler

Registered: 02/26/13
Posts: 2465
Loc: springtown,tx.
eBay has some from $199 and up. Magnets and epoxy also.
_________________________
22 ft. Wellcraft Deep V CC
817-220-2312
Bridgeport/Eagle Mountain/Possum Kingdom/ Lake Texoma
www.bobosguideservice.com
www.bobosthumper.com
www.nekidtackle.com Home of the RonRig!

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