flywheel will not come off!

[tampaaquasport81]

iv got a 91 200 johnson. iv tried everything to get the flywheel off but with no success. i used grade 8 bolts for the harmonic balancer puller, tightened down, and hit tool with hammer. that didn't work so i used a steel pipe for leverage to tighten, and out came one of the grade 8 bolts. any ideas?

 

[jonesg]

Re: flywheel will not come off!

drill and tap the stripped bolt for the next size up, tighten it up good then apply gentle heat , rap it good and give it time. Maybe try applying some penetrating fluid, more gentle heat, rap it again and give it more time.
patience and pursuasion.

 

[tashasdaddy]

Re: flywheel will not come off!

PULLING FLYWHEEL

you need a harmonic balancer puller, you need 3 - #8 harden bolts, that fit the 3 holes in your flywheel. standard hardware store bolts will strip out, causing more problems. loosen the flywheel nut, leaving it on so it protects the thread. thread the bolts in 7/16 of an inch. then tighten the puller, adjust so it has a straight pull. now tighten the puller, rap the center bolt with a hammer, then tighten some more. you may have to let it sit over nite, and repeat in the morning. this is a compression fitting, it will eventually POP!!. do not loose the woodruff key that goes in the groove of the flywheel and the crank shaft. then installing the flywheel, it has to be totally clean, no oil, woodruff key in place. then torque the nut to the specifications for your particular motor. if you do not do this, the woodruff key with shear, and you will be repeating these steps.


it will come off.

 

[lowkee]

Re: flywheel will not come off!

For the really PITA flywheels, penetrating lube (I'm fond of PB Blaster) and heat (A simple $10 propane torch) are your best friends. I've pulled hundreds of flywheels and never had one beat me using this method.

Any generic flywheel puller will work, just don't think the bolts are going to do your work for you.

Steps:

- Spray PB Blaster down the center
- Go get coffee (10-15mins)
- Put on the puller
- Heat with torch
- Use hammer (2-3 strikes)
- Tighten bolts a bit more
- Heat some more
- User hammer (2-3 strikes)
- Repeat above 3 steps.

Like JonesG said, patience wins out, not brute force.

EDIT: Just for clarity, the heat goes around the crank, on the flywheel itself, not on the crank itself. What the heat does is expand the metal around the crank to lessen the death grip it has on the crank.

Remember, the crankshaft is cone-shaped int at area, so you only need the flywheel to move a millimeter or two and it will take itself off after that.

 

[tashasdaddy]

Re: flywheel will not come off!

you can WARP your flywheel with heat, careful. i have never need heat to get one off, time and patience, yes.

 

[kenmyfam]

Re: flywheel will not come off!

As T/D time and patience will pay off.

 

[Mark_VTfisherman]

Re: flywheel will not come off!

you can WARP your flywheel with heat, careful. i have never need heat to get one off, time and patience, yes.

lowkee - Repeat above 3 steps.

This may two cups of coffee

tampaaquasport81: When he says heat, he doesn't mean roasting hot. Just a little hotter than the crankshaft taper is all that it takes- just heat circularly around the nose while the puller is at tension. Even heat and not much hotter than you can hold your fingers to. The flywheel-crank tapers are like an interference fit, but because they are tapered, the slightest movement and it will come off. (Hopefully this is not your issue, but the red-neck cure for a flywheel that keeps shearing is blue lock tite- dumb. I don't recommend doing that but I have seen it done. It releases when heated though. Heat is the only answer to getting it to let go of the taper in that case.)

Obviously you need to tap the threads out, but when you go to the next size, I would get the finer thread bolts and tap for the diameter you go to. The fine thread "ramp" has a smaller angle which introduces more pulling power, and while the find thread is more fragile in appearance, in use the fine thread can withstand more force.

When you run your bolts in, don't just tighten them up. Oil the threads, and run them just a hair past snug. Don't over tighten them. If the part of the flywheel you need to tap is aluminum, I might stick with the coarse thread though.

What tashasdaddy said is correct, it will come off, but be gentle with the puller, grasshopper.

 

[tampaaquasport81]

Re: flywheel will not come off!

yall's guidance, and my perseverance paid off!! retapped all 3 bolts to next size up.. tightened puller, slowly heated flywheel with torch till flywheel was warm, while gently tapping bottom of flywheel with mallet. and pop!! flywheel shot up and hit my buddy right in the face!! loud as hell and almost fell off the boat..
and my next question...
i haven't used the boat yet just got done restoring boat after i bought it from a guy about 6 mos. ago. he unplugged the vro pump and switched to premix.. he told me what the fuel to oil ratio was but i forgot... does anyone know what the mixture should be for a 91 johnson 200 looper? is it 50/1?

 

[Xcusme]

Re: flywheel will not come off!

Yup, 50:1 mix...

BTW...leave the flywheel nut on the crankshaft a couple of turns next time, prevents the flywheel from taking off into outer space.

 

[Faztbullet]

Re: flywheel will not come off!

Now that you got it off check the magnets for cracks or looseness are these engines are bad about magnet problems. Remove keyway and lap flywheel to crankshaft with fine valve grinding compound, Clean up and reinstall.

 

[tashasdaddy]

Re: flywheel will not come off!

besure to torque it, or you will be doing it again.

 

[Chiliando]

Re: flywheel will not come off!

Faztbullet,

What to do if the magnets have cracks. I have a 1999 225 ocean pro and found cracks in the magnets this morning.

What can I expect to happen because of the cracks?

Thanks in advance,

 

[Faztbullet]

Re: flywheel will not come off!

If the magnets are cracked they can splinter, slinging shards all in cowling,damaged stator,damaged cowling, possible ingestion by engine. Here is kit to repair magnets:
http://www.promarineusa.com/detail.aspx?ID=7408

Flywheel Magnet Kit
4304
Electrical
Kit containing 1 magnet and the epoxy to install it for OMC Looper flywheels.
$14.75

 

[Chiliando]

Re: flywheel will not come off!

Thanks!

I appreciate the help. This is a great forum.

 

[tampaaquasport81]

Re: flywheel will not come off!

magnets are ok, reinstalled everything, just went and picked up a torque wrench; i haven't purchased my manual yet but will do so in the next couple of days. in the meantime i'd like to torque it down to spec and get it running. does anyone know the torque setting for a 91 200?

 

[daselbee]

Re: flywheel will not come off!

My Evinrude manual for a '96 200 states that the flywheel nut should be torqued to 140-150 lbs-ft.
Clean the crank taper and the flywheel taper...no grease, etc.
The two motors will be the same, my bet.