1990 Merc XR4 - Flywheel Reinstall?

[dave621]

Ok, long story short as possible. I have a 1990 Mercury XR4 which I've been through two different mechanics 1 diagnosed the problem and went out of business which left me high and dry with a motor with the flywheel taken off and lost money for an ordered stator. Next mechanic I took it found that the Upper End Cap was shot due to holes being shaken to an oval shape instead of round and didn't think it was worth it to replace the upper end cap, stator, and maybe the trigger.

Ok so here's where I come in. I've had enough and decided to fix this thing myself. Got the factory manual, an upper end cap, and a stator. The trigger tested out ok. Now I have to put it back together which is no problem.

What I'm confused about and there might not be anything to be confused about is putting the flywheel back on. Does it have to go on in any particular fashion in relationship to the .462 mark or can it just be sat on then the flywheel nut tightened to 120 ft lbs which is what the manual calls for. I plan on doing a link n sync after putting it all back together again as well.

Any help is greatly appreciated

 

[j_martin]

Re: 1990 Merc XR4 - Flywheel Reinstall?

Ok, long story short as possible. I have a 1990 Mercury XR4 which I've been through two different mechanics 1 diagnosed the problem and went out of business which left me high and dry with a motor with the flywheel taken off and lost money for an ordered stator. Next mechanic I took it found that the Upper End Cap was shot due to holes being shaken to an oval shape instead of round and didn't think it was worth it to replace the upper end cap, stator, and maybe the trigger.

Ok so here's where I come in. I've had enough and decided to fix this thing myself. Got the factory manual, an upper end cap, and a stator. The trigger tested out ok. Now I have to put it back together which is no problem.

What I'm confused about and there might not be anything to be confused about is putting the flywheel back on. Does it have to go on in any particular fashion in relationship to the .462 mark or can it just be sat on then the flywheel nut tightened to 120 ft lbs which is what the manual calls for. I plan on doing a link n sync after putting it all back together again as well.

Any help is greatly appreciated

If you look real close you'll see that there is a key built into that hub spline. It'll only go on one way.

Could have saved ya some money on the upper bearing block. It's not to hard to drill and tap about 3 more holes in the cap, and a couple of the originals have room for a nut. Would have been better than new.

I usually drill and tap several extra mount holes any time I have a stator off. Not a big deal, and 4 little bolts just don't seem like enough to me. If there were room for duct tape, it'd get some of that, too.

Do a link-n-sync after you get it all together. Always worth the trouble.

hope it helps
john

 

[dave621]

Re: 1990 Merc XR4 - Flywheel Reinstall?

Thanks John, you made me feel a lot better about putting this thing back together again.

Dave

 

[j_martin]

Re: 1990 Merc XR4 - Flywheel Reinstall?

Thanks John, you made me feel a lot better about putting this thing back together again.

Dave

If yer used to wrenching on 4 cycle stuff, you soon discover that these things are about half as complicated.

If you can read the book and pay attention to detail, you'll do just fine. I figure the difference between the careless certified mechanic's work, and my student wrenching on the first one I've seen in my life without the covers is about 25 HP, and close to 10 MPH.