Frustrating Spark Problem.

[BoatBuoy]

Re: Frustrating Spark Problem.

If the tapers are damaged, here's the process that worked for another member, CATransplant:

"you must lap the flywheel
if you dont it will continue to shear keys.
get some medium lapping compound,remove the key and follow the instructions.. meaning apply the compound to the shaft, then place the flywheel on the shaft and rotate it back and forth aprrox 90*. then lift the wheel up move it 90* and repeat. the object is to make the two tapers fit again. when you think you are done carefully clean all surfaces with alcohol and place 3 pencil marks 120* apart. place the flywheel on the shaft and rotate it 90* while keeping the crankshaft locked. if all 3 pencil marks are wiped away your good to go. if not keep lapping."

 

[iwombat]

Re: Frustrating Spark Problem.

Look very hard at that key slot though and make sure you didn't chip the side out too badly when the key broke.

 

[charliegiggles]

Re: Frustrating Spark Problem.

The key slot on the crankshaft seems in fine condition. I'm saying seems because the slot does not appear to be damaged. I sheered the key slightly vertically "took a thin slice off it" perhaps from over torquing it. My new torque wrench does not "click" like it's suppose to so I'm taking it back and getting a new one along with another key.

The key fits snug in the crank slot and doesn't move when I intall the flywheel. I believe I overtorqued it and sheered the key "slightly" along the length.

In over torquing it the flywheel slightly rubbed off a "bit" of the coil casings however the coil is still not exposed.

Are we having fun yet? I sure seem to be running into alot of stumbling blocks. This is by the way a 73 evinrude so I am not sure what people before me did to it but I'm discovering and trying to make the best of it.

On another note I took the head off and will have a helix coil installed so no more gas leaks out. I can tell after taking the head off that the lower cylinder was running much cooler as there is more significant carbon deposits most likely from a leaking spark plug hole.

Anyways hopefully things will start going in the right direction.

 

[steelespike]

Re: Frustrating Spark Problem.

If you over torqued the flywheel you may have damaged the point cam.I believe it is removeable it may be cracked and have to be replaced.It is also possible you distorted the flywheel bore as well.I have to wonder if you might damage the cam again if the flywheel bore is stretched.

 

[charliegiggles]

Re: Frustrating Spark Problem.

Well I got a proper torque wrench and new key. The new key and flywheel went together smoothly and snug. I then rotated the flywheel to make sure it wasn't rubbing on anything and realized that there's no way I previously torqued it to 100lbs. I was probably somewhere around 60-70 however didn't install the key properly the first time around.
This time I just slightly set the key in the camshaft slot and slowly lowered the flywheel and miraculously everything just seemed to fit like a glove.

I did a spark test and have a nice blue spark that cracks on both spark plug wires using the screwdriver test.

Thanks to everyone for your advice. Luckily I didn't damage anything. Both the slot on the camshaft and flywheel appear to be in perfect condition. One thing I did notice is the key I purchased appears to be made out of a much softer metal so this probably helped save the day...