1968 evinrude flywheel removal

[tomasking]

Hi, I have a 1968 evinrude 40hp big twin #40853. I need to remove the flywheel. I have a puller but the thing just will not come off. Anyone have any idea what I might do to get it off?<br />thanks<br />tomas king

 

[Paul Moir]

Re: 1968 evinrude flywheel removal

What type of puller are you using? Are you trying to fix a weak spark or no spark problem?

 

[tomasking]

Re: 1968 evinrude flywheel removal

its a slide hammer type with three holes. I threaded bolts into the flywheel to attach it.

 

[Paul Moir]

Re: 1968 evinrude flywheel removal

It's going to be real tough to remove the flywheel with a slide hammer. Do you happen to have a harmonic balancer puller available?<br /><br />

 

[tomasking]

Re: 1968 evinrude flywheel removal

whoops, its a flange type puller not a slide hammer

 

[tomasking]

Re: 1968 evinrude flywheel removal

The puller I have looks like teh one in the photo, Is there anything I need to remove besides the three bolts and the main nut in the center before the flywheel comes off? Is there a snap ring or anything in there?<br />thanks

 

[Paul Moir]

Re: 1968 evinrude flywheel removal

No there isn't. <br />Here's my procedure for removing them: Tighten up the center bolt on the puller to about 30-50ft/lbs. If it doesn't pop at that, lift up on the puller and flywheel together to take the weight off the crankshaft bearings, and strike the center bolt with a hammer. Tighten and repeat.<br />If that doesn't help, it's time to hit the hub of the flywheel with a torch to heat it up.<br /><br />If the flywheel woodruff key has sheared (which causes lost or weak spark) the flywheel can be a real pain in the neck to remove.

 

[tomasking]

Re: 1968 evinrude flywheel removal

well I set the puller up like the photo and tried everything you said except the torch. The bolts holding on the puller just keep breaking. How big a job and how much money is it to fix a sheared woodruff key? I am considering a new outboard here.<br />thanks so much for your help<br />tomas

 

[Paul Moir]

Re: 1968 evinrude flywheel removal

The key is about $3, and you just need to clean up the taper with sandpaper/file and a little valve grinding compound to finish it off. Not a big deal at all.<br />Don't get frustrated. Those bolts in my puller are Grade 8 for a reason. If you don't have a torch handy, tension the flywheel up, spray the joint with a quality penetrating oil, and walk away from it for a day or so. It's a good idea to thread the nut on a bit first because sometimes when it lets go the flywheel will jump right off the outboard. It will make a horrible noise when it does - that's ok.<br /><br />PS - the flywheel key P/N over at http://www.evinrude.com/en-US/Accessories/Engine.Diagrams.htm is incorrect. That's for 5 keys. The correct number is 302602.<br />CATransplant has an excellent post about cleaning up the flywheel here: http://www.iboats.com/cgi-bin/ubb/ultimatebb.cgi?ubb=get_topic;f=28;t=029310#000017

 

[CATransplant]

Re: 1968 evinrude flywheel removal

Get new puller bolts, but make sure they're Grade 8 bolts, and put Grade 8 washers under them. That will help keep the pressure on your flywheel.<br /><br />The flywheel is probably jammed on the crankshaft taper due to smeared metal from the sheared key.<br /><br />With the Grade 8 bolts, you can put about 80 ft-lbs of pressure on the puller bolt. If that doesn't pop it off, try Paul's tips again.<br /><br />Another thing to do is to put that torque on the bolt, then just go away for a day or two. It's amazing how many times that will pop the flywheel off. The steady pressure will eventually do the job.